Kayasand

What Kayasand does

Kayasand Limited is a New Zealand-incorporated private company, headquartered in Hamilton, Waikato, that designs, manufactures, and licenses dry processing plants for sand manufacturing and aggregate separation. Founded in 2006 by Andi Lusty after his tenure leading global Barmac crusher sales, the company is the exclusive licensed distributor of Kemco's proprietary V7 sand engineering technology and RCAS quad-deck air screen systems for Australia, New Zealand, and the South Pacific Islands.

The company's core products are the V7 sand engineering plant (available in V7-40, V7-60, V7-120, and V7-240 models with throughputs of 40–240 TPH) and the RCAS air screen range (RCAS 900 through RCAS 2500). The V7 system is a fully dry, waterless process that uses proprietary crushing and air classification to convert quarry crusher dust, recycled glass, recycled concrete, and slag into cuboidal, precisely graded, contamination-free engineered sand for concrete. Plants support 24/7 unmanned autonomous operation via an in-house sensor and control stack with remote monitoring.

Kayasand sells turnkey plant installations directly to enterprise quarry operators and concrete manufacturers across Australia, New Zealand, and the South Pacific, with named field-sales coverage in NZ (CEO Bram Smith) and Australia (Sales Manager Frank Grech). The customer base includes global building materials majors Holcim (Albion Park V7-60, 2016) and Heidelberg Materials (Bass Point V7-120, July 2025, multi-million dollar), alongside APD and Conset Construction, with engineered sand enabling up to 20% cement reduction and ~6,000 tonnes/year CO2 savings per plant. The company has set a public target of 40 plants operating across NZ and Australia by 2030.

Name

Kayasand

Legal name

Kayasand Limited

Website

https://kayasand.com

Company type

Private

Founded year

2006

Operating status

Operating

Headcount range

11–50 employees

Short description

Kayasand is a New Zealand-based private company that licenses Kemco's proprietary V7 dry sand engineering technology, designing and selling turnkey plants that convert quarry crusher dust into engineered sand for concrete across Australia, New Zealand, and the South Pacific.

Ownership category

akta.pro rank

Headquarters

HQ city

Hamilton

HQ country

New Zealand

HQ region

Oceania

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Technology or R&D, Supply Chain, Personnel, Operations, Marketing or Sales, Infrastructure

Revenue model

1. V7 Sand Plant Equipment Sales & Licensing: Kayasand sells and licenses Kemco's V7 sand engineering plant technology to quarry operators. Plants are sold as turnkey installations (design, supply, installation, commissioning). The company also generates revenue from servicing, remote monitoring, and ongoing support contracts. Kayasand is the licensed Kemco distributor for Australia, New Zealand, and the South Pacific Islands.
2. RCAS Air Screen System Sales: Sale of RCAS quad-deck vibrating air screen systems to quarries for high-throughput dry screening and de-dusting of coarse and fine aggregates. Systems are sized to suit quarry operations (RCAS 900 through RCAS 2500).
3. Plant Design, Installation & Support Services: Turnkey plant installation, remote monitoring, servicing, and ongoing technical support provided to quarry operators as part of the plant supply package.

Go-to-market motion2 records

Distribution channels3 records

Marketing channels6 records

Core offering

Kayasand designs, manufactures, and sells dry processing plants for sand manufacturing and aggregate separation. Its core offering is the Kemco V7 sand engineering plant and RCAS quad-deck air screen systems, which convert quarry crusher dust and other byproducts into cuboidal, precisely graded engineered sand for concrete. The company is the licensed Kemco distributor for Australia, New Zealand, and the South Pacific Islands, providing turnkey plant design, installation, commissioning, remote monitoring, and ongoing support.

Product overview

Kayasand offers a portfolio of sand manufacturing and fine aggregate processing solutions centered on Kemco's proprietary V7 sand engineering plant technology and RCAS quad-deck air screen systems. The V7 plants (V7-40, V7-60, V7-120, V7-240) are dry processing systems that convert quarry byproducts like crusher dust into precision-engineered sand for concrete. RCAS air screens provide high-throughput aggregate screening. Together, these products enable quarries to transform waste materials into premium construction sand while reducing cement usage by up to 20%.

Differentiator

Problem solved

Functional benefit

Products and services

• V7 Sand Engineering Plant A completely dry sand engineering system that precision-manufactures high-quality concrete sand from quarry byproducts (crusher dust, recycled glass, recycled concrete, and slag). Features crushing, screening, conditioning, and ultrafine collection in a single system. Available in four sizes: V7-40 (40 TPH, 290kW), V7-60 (60 TPH), V7-120 (120 TPH), and V7-240 (240 TPH, 1520kW), with production capacity ranging from 100,000 to 600,000+ tonnes per annum depending on model. Targets quarry operators and concrete manufacturers seeking a sustainable alternative to natural sand dredging.
• RCAS Quad-Deck Air Screen Systems High throughput, precision screening system for dry screening and de-dusting fine aggregates. Combines the accuracy of vibrating screens with the throughput of air classification. Extracts and processes up to 7 different product fractions simultaneously (40mm to <0.075mm). Available in four sizes: RCAS 900, RCAS 1200, RCAS 1900, and RCAS 2500. Designed for quarry operators needing dry screening solutions without water usage.
• Engineered Sand Premium sand specifically engineered for use in concrete, produced from crusher dust, recycled glass, recycled concrete, and slag using the V7 plant process. Features ideal cuboidal shape for pumpability and workability, precise sizing and grading for packing density, contaminant removal, and consistent quality regardless of feed changes. Replaces 100% of natural sand in concrete and enables up to 20% cement reduction while producing stronger concrete (24% strength increase observed in trials). Sold by Kayasand and its customers (e.g., Holcim) to concrete manufacturers.
• Sand Engineering Technology Licensing and Plant Services Technology licensing and full turnkey plant services for V7 sand engineering plants and RCAS air screen systems. Includes plant design, supply, installation, commissioning, remote monitoring, servicing, and ongoing technical support. Kayasand operates as the exclusive licensed Kemco distributor for Australia, New Zealand, and the South Pacific Islands, with referrals to Kemco directly for other territories.

Quantifiable outcome

• Up to 20% cement reduction in concrete, saving 6,000 tonnes of CO2 emissions per plant per year
• +6 more outcomes

Named customers5 records

Segments3 records

Ideal customer profiles3 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature5 records

Partnerships

Six partnerships are on record, tiered core, flagship and minor.

• Kemco Co., Ltd.coreTechnology or IntegrationKayasand is the licensed distributor of Kemco's proprietary V7 sand making technology and RCAS air screen systems for Australia, New Zealand, and South Pacific Islands. The V7 technology was originally developed by Kemco's chief engineer, Dr Kaya, in Japan. Kayasand was named after the technology's inventor. The company sells, installs, and supports Kemco equipment as its exclusive licensed channel partner in the specified territories.
• Holcim (Australia)coreChannel Partner/ Reseller/ DistributorIn 2016 Kayasand installed and commissioned the first V7-60 plant outside of Asia at Holcim's Albion Park Quarry in Australia. Holcim uses the Kayasand plant to produce and sell premium manufactured sand to concrete manufacturers in the Sydney market. Holcim acts as both a customer of the technology and a reference site for Kayasand's Asia-Pacific operations.
• Heidelberg Materials AustraliaflagshipStrategic or Co-development PartnerKayasand signed a landmark multi-million dollar deal in July 2025 with Heidelberg Materials to install a V7-120 dry processing plant at Bass Point Quarry in NSW, Australia. The plant will convert crusher dust into 300,000+ tonnes of high-quality engineered sand annually. Heidelberg Materials is a major global building materials leader and key infrastructure supplier in Australia. The deal represents Kayasand's largest commercial installation to date.
• APDcoreStrategic or Co-development PartnerAPD, a manufacturer of Stormwater and Wastewater management solutions, partnered with Kayasand to pour New Zealand's first factory floor using 100% manufactured sand. The APD factory floor pour in February 2025 at Wiri was a milestone commercial demonstration of Kayasand's engineered sand technology. APD has a strong environmental focus and sourced Kayasand's sand specifically to minimise the environmental impact and carbon footprint of their new factory floor.
• Alex Fraser GroupminorStrategic or Co-development PartnerAlex Fraser and Kayasand co-presented at an IQA (Institute of Quarrying Australia) event in November 2024, championing sustainability in the aggregates and concrete industry. The partnership involves joint industry advocacy and knowledge sharing around sustainable sand manufacturing.
• Conset ConstructionminorStrategic or Co-development PartnerConset Construction, specialists in design and build of large pour flat slabs, partnered with Kayasand to lead the groundbreaking APD factory floor pour — New Zealand's first commercial pour using 100% manufactured sand. The complex high-stakes pour demonstrated the performance of Kayasand's engineered sand in a demanding concrete application.

Scale indicators12 records

Recent moves10 records

Expansion highlights6 records

Broad incumbents

• Metso: Metso (formerly Metso Outotec) is the global leader in aggregates and mining processing equipment, including Barmac vertical shaft impact crushers that compete with Kemco V7 in the manufactured/engineered sand market. Kayasand's founder spent 30 years selling Barmac before founding the company.
• Terex Corporation: Terex manufactures crushing, screening, and material handling equipment for quarrying, construction, and recycling through brands like Terex Finlay and Powerscreen. It competes with Kayasand in aggregate processing equipment, particularly in mobile and modular sand production systems.
• Astec Industries: Astec Industries designs and manufactures equipment for the aggregate, asphalt, and infrastructure industries, including crushing and screening systems that overlap with Kayasand's V7 and RCAS offerings for quarry operators.
• Sandvik: Sandvik is a major global mining and rock processing equipment manufacturer offering crushers, screens, and material handling solutions for quarries and aggregate producers. It overlaps with Kayasand in serving quarry operators with capital equipment for sand and aggregate processing.

Others

• Alex Fraser Group: Alex Fraser is an Australian recycled construction materials company and a Kayasand partner (joint IQA presentations). It is a potential customer/operator of Kayasand plants and competes indirectly as a sustainable aggregate supplier.
• Kemco (Co., Ltd.): Kemco is the Japanese engineering company that developed and owns the V7 sand engineering technology that Kayasand licenses. It is Kayasand's principal technology partner and supplier, and directly competes in non-Kayasand geographies (Japan, China, India).

Direct peers

• McLanahan Corporation: McLanahan designs, manufactures, and installs processing equipment for aggregate, mineral, and recycling industries, including sand processing and washing systems. It is comparable to Kayasand in serving quarries with engineered sand solutions.
• CDE Group: CDE is a specialist manufacturer of wet and dry sand processing systems for quarries, including engineered sand plants. It is the closest direct competitor to Kayasand's V7 system, focused specifically on turning quarry byproducts into specification construction sand, though it emphasises wet processing rather than Kayasand's dry approach.

Emerging players

• Superior Industries: Superior Industries manufactures crushing, screening, and material handling equipment for aggregate producers, with growing emphasis on manufactured sand solutions. Comparable to Kayasand as a focused aggregate equipment supplier.

Regional players

• Hub-Group (Stelco): Various Australian and New Zealand-based aggregate processing equipment suppliers and engineering firms compete with Kayasand in the local market for quarry sand plant installations, often offering wet-processing alternatives.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks5 records

Key highlights7 records

Customer concentration

• YouTubeyoutube.com/@KayasandNZ
• LinkedInlinkedin.com/company/kayasand
• Xx.com/kayasand

Revenue estimate

Valuation estimate

Number of profiles

Profiles6 records

Funding overview

Funding rounds6 records

Investors5 records

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Kayasand