Manish Bhartia, Brendan McGurgan and Enda Ivanoff showcase how they developed the patented innovation known as Combo for the quarrying and aggregates sector.
When Apple launched the first iPhone, it did more than introduce a new gadget. It completely changed how people interacted with technology by combining a camera, music player, and computer into one elegant, portable device. A similar revolution has taken place in the world of sand and mineral processing through Combo – a breakthrough patented innovation from CFlo.
Before Combo, traditional sand washing plants were enormous installations that stretched across large areas of land.
They consumed huge amounts of water and electricity and often left behind massive sludge ponds that created long-term environmental issues. These systems were able to produce washed sand, but they were inefficient, resource intensive, and unsustainable.
More than a decade ago, a small group of engineers at CFlo decided to change that reality. Their vision was clear – to integrate all stages of wet processing, including feeding, screening, washing, classification, water recovery, and waste management, into a single, compact, and mobile system. It has reshaped how sand and aggregate processing is done around the world.
Developing the idea
When the concept was first presented, many industry veterans were skeptical. The idea of combining multiple wet processing stages into a single unit sounded risky and overly complex. “There are too many components, too many moving parts. Keep them separate,” was the common feedback. To prove the concept, the CFlo team began by offering all the required process equipment – feeders, screens, cyclones, pumps, sumps, thickeners, conveyors, and control systems – as a pre-engineered kit that could be delivered and assembled at site. The approach worked. Clients appreciated the simplicity and reliability of the kits.
This raised another question: “Why not deliver the whole setup ready to use – preassembled, prewired, and easy to install?”.
That question sparked the creation of Combo.
The engineers at CFlo designed a single, integrated chassis that housed every essential process step. They developed new methods to reduce water and energy consumption and created a much smaller footprint that eliminated the need for large settling ponds. Every challenge presented an opportunity for innovation. After several design cycles and trials, the first Combo was built and tested. The results were remarkable. The system performed better than expected, producing high-quality washed sand while dramatically lowering water and power usage.
Integrated version
When CFlo entered the wet processing market, it asked a simple but critical question: why should water recycling sit outside the plant as an optional extra? If water is essential, water recovery should be designed into the system itself. That single question shaped the development of the Combo series. According to CFlo, this is the one of the world’s first patented chassis to integrate all seven functions of wet processing: feeding, screening, classification, dewatering, water recovery, sludge handling, and stockpiling on one containerised frame.
The water recycling system, WRS, is a standout function. Unlike conventional thickeners that require heavy concrete pads and large open areas, the WRS is mounted directly on the Combo chassis. It is factory-built, self-standing, and fully mobile.
In select projects, CFlo has even supplied Combo units with precast civil pad segments that are bolted together on site. The entire system can be relocated with the machine, making it highly practical for short-duration or multi-site operations.
This design makes closed-loop water recycling not only possible but practical. Thanks to its patented design, recycled water flows back into the process by gravity, eliminating the need for additional pumps. This reduces power use by up to 30 percent, making Combo one of the most energy-efficient systems in its class.
Sludge management, traditionally a major pain point for washing plants, has also been re-engineered. Conventional sludge ponds demand huge land areas, long settlement times, and constant maintenance. They are often unsafe and environmentally unsustainable. CFlo’s easysettle sludge bay manager replaces this with a modular system that controls inflow, manages settling, and optimises dewatering. Effluent water is clarified and returned to the process, leaving no open discharge. Land use is significantly reduced, and the sludge is easier to compact, handle, and reuse. Importantly, the easysettle system is also mounted on the Combo chassis, allowing it to move wherever the plant goes.
Together, the WRS and easysettle systems make Combo not just compact and mobile but also smarter, cleaner, and more sustainable. In other words. a complete solution for the future of wet processing.
The changing face of sand
Combo represented more than just a new product. It marked a complete shift in how the industry approached wet processing. By integrating all major functions into one mobile and modular platform, CFlo delivered a solution that was efficient, sustainable, and far easier to deploy than conventional plants.
This design earned multiple patents across major markets, including the US, for innovations in water recovery, material handling, and modular construction. What once seemed like an experimental idea has now become a proven technology, trusted by hundreds of customers around the world. Today, more than 300 Combo units operate successfully in 17 countries, and many of the world’s leading mining and construction companies now use multiple systems for their large-scale projects.
Efficient and economic
Combo is not only an environmental innovation; it is also a powerful economic tool. Across hundreds of installations worldwide, Combo units have logged tens of thousands of operating hours.
They have processed millions of tonnes of raw sand, overburden, and quarry fines into valuable, construction-ready materials – clean sand, graded stone, and recovered clay.
For operators, the numbers tell a clear story. The typical investment in a Combo system is recovered quickly through savings in water, power, and maintenance. The technology consistently delivers strong cash returns throughout its 15-year design life. With lower operating costs and higher product recovery, Combo has proven to be a profit engine as well as a production machine.
Unlike traditional washing plants that depend on multiple civil structures, Combo’s modular design allows for easy relocation and rapid installation. A new site can be commissioned in weeks rather than months, reducing downtime and improving overall productivity.
Built for the long run
Each Combo system is engineered for durability and efficiency. Designed to operate around 6000 hours per year, the system can comfortably handle a wide range of feed materials – from river sand and crushed rock fines to construction and demolition waste. Its automated controls and closed-loop water management system minimise operator intervention while maximising yield.
Over its lifetime, a single Combo unit can convert millions of tonnes of waste material into marketable products. This results in a major reduction in natural sand extraction, significant water savings, and measurable reductions in carbon emissions.
More than a machine
Combo has become more than a product line. It has become a symbol of what innovation can achieve when guided by purpose. By turning waste into resources, reducing environmental impact, and improving profitability for operators, it bridges the gap between sustainability and performance. While some continue to imitate its original design concept, it is hard to replicate the technology, or customer experience that Combo has created over the years. Combo was a true “iPhone moment” for the industry and sustainable sand processing.
Combo has proven that genuine innovation does not just improve processes – it redefines what is possible. AB
