1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that cap profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant represents a critical production tier where inefficiencies translate into significant financial impact. Common challenges include:
Inconsistent Throughput: Unplanned downtime from feeder to crusher mismatches or conveyor bottlenecks, losing hundreds of tons per shift.
High Operational Costs: Spiking wear part consumption in secondary/tertiary stages and excessive energy use per ton of finished aggregate.
Product Quality Variance: Inability to consistently meet multiple spec products (e.g., 3/4" aggregate, 1/2" chips, manufactured sand) from variable feed material.
Excessive Footprint & Setup Time: Modular plants that require extensive civil works and complex interconnection, delaying commissioning and ROI.

The central question is: how do you achieve reliable 250300tph output with lower costperton, simplified maintenance, and the flexibility to adapt to changing project demands?

2. PRODUCT OVERVIEW

This 250300tph stationary stone crushing plant is a complete, engineered solution designed for continuous, highvolume production of aggregates for road base, concrete, and asphalt applications. It is configured for primary, secondary, and tertiary crushing stages to produce precisely graded end products.

Operational Workflow:
1. Primary Reduction: Large quarryrun rock (up to 750mm) is fed into a primary jaw crusher for initial size reduction.
2. Secondary Crushing & Screening: The output is conveyed to a secondary cone crusher. A primary screen separates sized material, routing oversize back for further crushing.
3. Tertiary Shaping & Final Sizing: Material requiring additional shaping is processed through a tertiary cone or impact crusher. Final screening decks separate the output into 35 specified product stockpiles.

Application Scope: Ideal for dedicated aggregate quarries, large infrastructure project support bases, and highdemand commercial concrete operations.
Limitations: This plant configuration requires stable, hard rock feed (granite, basalt, limestone). For very abrasive or highsilica content materials, specific liner metallurgy is recommended. It is not a portable solution and requires planned foundation work.

3. CORE FEATURES

Modular PreAssembly | Technical Basis: Skidmounted major component assemblies | Operational Benefit: Reduces onsite installation time by up to 40% versus componentbycomponent builds | ROI Impact: Faster commissioning allows revenue generation to begin weeks earlier.

Intelligent Crushing Chamber Design | Technical Basis: Optimized cavity geometry and kinematics | Operational Benefit: Increases yield of inspec product on first pass by an estimated 1520%, reducing recirculating load | ROI Impact: Directly lowers energy consumption and wear on crushers per ton of final product.

Centralized PLC Automation System | Technical Basis: Programmable Logic Controller with touchscreen HMI | Operational Benefit: Enables singleoperator control of the entire flow, monitors motor loads, and provides fault diagnostics | ROI Impact: Reduces labor requirements for routine operation and minimizes downtime through predictive alerts.

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Robust sectionalized grizzly bars & high Gforce vibration | Operational Benefit: Effectively scalps fines ahead of the primary crusher and ensures consistent, regulated feed | ROI Impact: Protects primary crusher from unnecessary wear caused by fines packing and prevents chokefeeding.

Unified Walkway & Maintenance Access | Technical Basis: Integrated platform design around all major service points | Operational Benefit: Provides safe, easy access for daily inspections, liner changes, and belt maintenance | ROI Impact: Cuts scheduled maintenance time significantly improves technician safety compliance.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 250300tph Plants | This Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Tonnage Consistency (Monthly Availability) | 9294% operational availability | >96% operational availability (design target) | +24% availability |
| Energy Consumption (kWh/ton) Varies by rock type. Baseline set at industry average. Industry Average Baseline = X kWh/ton Estimated X 0.88 kWh/ton Estimated reduction of ~12% |
| Wear Cost ($/ton) Secondary Stage Secondary Crusher Wear Cost Secondary Crusher Wear Cost Focus on chamber design & material flow reduces abrasive wear Estimated reduction of ~1015% |
| OnSite Commissioning Time (Weeks) Componentbycomponent build Modular skid assembly Field data shows reduction of ~3040% |

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 250 300 metric tons per hour (275 330 US tph), dependent on feed material hardness and size distribution.
Primary Crusher: Jaw Crusher Model [e.g., JC5460], Feed Opening suitable for up to 750mm rock.
Secondary Crusher: Cone Crusher Model [e.g., MC350], with hydraulic adjustment and clearing.
Tertiary Crusher: Cone or Vertical Shaft Impact (VSI) Crusher Model [e.g., TC260 or VSI2800] for shaping/fine production.
Screening Units: Multideck vibrating screens (typically 23 units), sizes tailored to final product specifications.
Power Requirements: Total installed power approximately 800 1000 kW. Requires dedicated highvoltage connection as per local grid.
Key Material Specifications: Main frame structure; Heavyduty steel plate. Conveyor idlers; CEMA C/D rated bearings. Screen meshes; Hightensile wire or polyurethane panels.
Approximate Footprint (L x W): ~85m x 45m (280' x 150'), subject to final layout configuration.
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature with appropriate lubrication systems.

6. APPLICATION SCENARIOS

[Regional Granite Quarry] Challenge: An established quarry needed to upgrade from a 200tph system to meet new highway contract demands without expanding its operational footprint or significantly increasing crew size.

[Large Infrastructure Project Dam Construction] Challenge: A remote dam construction site required consistent production of multiple aggregate specifications (from riprap to fine aggregates) with limited technical personnel available onsite.

[Commercial Asphalt Producer] Challenge: A producer aimed to increase yield of highvalue manufactured sand from their limestone feed while maintaining strict gradation control for asphalt mixes.

[Solution]: Implementation of this modulardesigned plant allowed the existing footprint to be utilized efficiently. The centralized PLC system enabled management of the higher throughput with the same operator team.

[Solution]: A ruggedized version was supplied with preassembled modules. The design prioritized reliability over ultimate flexibility.

[Solution]: Integration included a tertiary stage VSI crusher. The automation system was programmed with specific recipes for different sand products.

[Results]: Achieved sustained output of 280tph. Plant availability increased from under 95%, meeting supply obligations on schedule without added labor costs.

[Results]: Plant commissioned in months typical timeline). Achieved reliable >260tph output in harsh conditions with minimal specialist intervention required.

[Results]: Increased saleable sand yield by >22%. Product consistency improved dramatically. Allowed entry into new markets requiring precise filler material.

7. COMMERCIAL CONSIDERATIONS

Our solutions are offered in clear pricing tiers based on core configuration:

Tier A – Base Plant Configuration includes primary jaw crusher secondary cone crushers primary screen core conveyors central control cabin
Tier B – Enhanced Configuration adds tertiary crushing stage additional final screening decks dust suppression system
Tier C – Turnkey Premium Configuration includes all above plus full electrical switchgear package advanced automation with production reporting preassembly services

Optional features include automated lubrication systems metal detection tramp iron relief systems sound enclosures

Service packages are available separately ranging from basic commissioning supervision through comprehensive multiyear maintenance agreements including parts kits

Financing options can be discussed including equipment leasing structures tailored for capital expenditure cycles typical in the aggregates industry

8.FAQ

Q1 Is this plant compatible with our existing primary feeding system or stacker conveyor?
A1 Yes provided your existing feeder or stacker can handle the required steadystate tonnage up to Our engineering team can review interface points like hopper dimensions discharge heights transfer chute designs

Q2 What is the expected operational impact during liner changes on the secondary cone crushers?
A2 With standard tooling field data indicates a trained twoperson crew can complete mantle concave replacement in Downtime can be further reduced with optional hydraulic assist kits

Q3 How does this plant manage variations in feed material hardness which we commonly experience?
A3 The PLC system monitors motor loads adjusting feeder rates accordingly Secondary tertiary crushers feature hydraulic adjustment allowing closedside setting changes under load within limits adapting quickly without stopping production

Q4 Are spare parts packages included in the initial purchase price?
A4 No spare parts are quoted separately We recommend an initial wear parts kit based on projected This ensures critical components are on hand minimizing potential downtime due to logistics delays

Q5 What level of operator training is provided?
A5 Comprehensive training is included covering normal operation startup shutdown sequences basic troubleshooting safety procedures Training occurs during commissioning both classroom style handson at controls Typically spans

Q6 Can this plant be reconfigured later if our product focus shifts e.g more emphasis on manufactured sand?
A6 The modular design allows reconfiguration Adding a VSI crusher as an additional tertiary stage or modifying screen decks are common future modifications Civil foundation planning initially considers such potential expansions

Q7 What are standard payment terms delivery lead times?
A7 Standard commercial terms involve progress payments tied milestones like order confirmation completion factory testing shipment Lead times typically range order confirmation depending current manufacturing schedule complexity chosen options