1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant is a critical asset, yet standard configurations often introduce costly inefficiencies. Common challenges include:
Unscheduled Downtime: Frequent mechanical failures in crushers or feeders halt your entire production line, costing thousands per hour in lost output and labor.
Inconsistent Final Product Quality: Poorly calibrated or mismatched crushing stages produce offspec aggregate, leading to material waste and rejected loads.
High Operational Costs: Spiking energy consumption from inefficient drives and excessive wear part replacement directly impact your bottom line.
Scalability Limitations: Inflexible plant design struggles to adapt to changing feed material hardness or required product gradation shifts.

Is your current setup delivering the reliable, costperton output required for competitive bidding and sustained project margins? The solution lies not just in equipment, but in an engineered system designed for this specific throughput class.

2. PRODUCT OVERVIEW

This 250300tph stationary stone crushing plant is a complete, preengineered processing solution designed for highvolume production of aggregates for construction, road base, and railway ballast. Engineered as a cohesive system rather than a collection of individual machines, it transforms raw quarry rock into precisely graded finished products.

Operational Workflow:
1. Primary Crushing & Feeding: Dump trucks feed raw material into a robust vibrating grizzly feeder, which scalps out fines and directs oversize to a heavyduty primary jaw crusher.
2. Secondary & Tertiary Reduction: Primary crushed material is conveyed to a secondary cone crusher for further size reduction. A tertiary cone crusher or impact crusher stage then finetunes the product shape and size.
3. Sizing & Sorting: Material is routed to a multideck vibrating screen where it is sorted into specified size fractions.
4. Stockpiling & Recirculation: Onspec material is conveyed to designated stockpiles. Oversize material is automatically recirculated back to the appropriate crusher in a closedloop circuit.

Application Scope: Ideal for granite, basalt, limestone, and river gravel. Best suited for fixedlocation quarries or large infrastructure project sites with a lifespan exceeding 18 months.

Limitations: Not designed for highly abrasive materials (e.g., certain silicarich ores) without specific liner options. Requires stable, prepared foundation and gridbased power supply.

3. CORE FEATURES

Modular Skid Design | Technical Basis: Preassembled steel structure with integrated walkways and ladders | Operational Benefit: Reduces onsite installation time by up to 40%, minimizing civil works and accelerating commissioning | ROI Impact: Faster timetorevenue; lower installation labor costs

Intelligent Crushing Chamber Automation | Technical Basis: Hydroset or similar cavity clearing & adjustment system on cone crushers | Operational Benefit: Allows operators to adjust discharge settings remotely to compensate for feed variations, maintaining consistent product gradation | ROI Impact: Reduces product waste by an estimated 35%, maximizing saleable yield

Centralized PLC Control System | Technical Basis: Programmable Logic Controller with humanmachine interface (HMI) panel | Operational Benefit: Enables singlepoint monitoring of motor loads, conveyor speeds, and bin levels; provides automatic sequencing for startup/shutdown | ROI Impact: Optimizes energy use; reduces operator error; allows operation with fewer personnel

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Highstrength steel deck with adjustable grizzly bars | Operational Benefit: Removes subfines before the primary crusher, reducing chamber volume usage and wear on primary liners | ROI Impact: Extends primary wear part life by 1520%; increases effective primary crusher capacity

MultiStage Dust Suppression Integration | Technical Basis: Strategically placed spray nozzles at transfer points with solenoid valve control | Operational Benefit: Significantly suppresses airborne particulate at source points, improving site visibility and environmental compliance | ROI Impact: Mitigates risk of regulatory fines; reduces health & safety incidents

HighAbrasion Conveyor Systems | Technical Basis: Chevron pattern belts with impact beds at loading zones | Operational Benefit: Minimizes material spillage and belt damage from sharpedged aggregate at high transfer points | ROI Impact: Lowers belt replacement frequency and cleanup labor costs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | Our 250300tph Stone Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Mechanical Availability | 88 92% (estimated) |>94% (contractually backed) |> +3% (Reduced Downtime) |
| Energy Consumption per Ton Processed| Baseline (100%)| Optimized drive systems & efficient motor selection| Up to 8% |
| Wear Part Life (Primary Crusher Jaws) Varies by material.| Industry average benchmark.| Proprietary manganese steel composition & chamber design.| +15% to +25% |
| Product Shape Index (Cubicity)| Dependent on secondary stage type.| Optimized tertiary crushing stage configuration.| Improved consistency; field data shows >10% reduction in flaky content.|
| Installation & Commissioning Time| 68 weeks postfoundation.| Preassembled modules reduce field work.| 30% to 40% |

_Based on OEM field service data under normal operating conditions._

5. TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: 250 300 metric tons per hour (varies based on feed material hardness and product size).
Primary Power Requirement: Approx. 550 650 kW total connected load (dependent on final configuration).
Feed Size Maximum: Up to 750mm edge length.
Final Product Range: Capable of producing 05mm sand up to 40mm aggregate concurrently.
Key Material Specifications:
Primary Crusher Frame: Welded steel plate (Q345B/equivalent).
Cone Crusher Liners / Jaw Plates: High manganese steel (Mn18Cr2/equivalent).
Screen Mesh Decks: Harwire tensioned decks or polyurethane panels.
Approximate Footprint: ~65m L x 45m W x 15m H (varies with layout).
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dust suppression system rated for effective operation up to 85% relative humidity.

6. APPLICATION SCENARIOS

Highway Construction Project Consortium

Challenge: Required consistent supply of over 5000 tons/day of multiple aggregate specifications across three separate work fronts within a tight project timeline. Standard mobile units could not meet volume demands reliably.
Solution: Implementation of two parallel lines of our standardized modular crushing plants configured specifically for their granite feed. Centralized control allowed one team to oversee both lines.
Results: Achieved sustained output of over600 tph across both plants. Met all gradation specifications for subbase, base course,and asphalt chips without recrushing. Project completed the aggregate phase12 days ahead of schedule.

LargeScale Commercial Quarry Operator

Challenge: Aging fixed plant suffered from declining availability (<85%)and rising maintenance costs,causing missed shipment schedules. Inconsistent product shape ledto customer complaints about performancein concrete mix designs.
Solution: Complete turnkey replacementwith our optimized tertiary configurationplant,focusingon cubicityin the final stages.The intelligent control system was integrated into their existing quarry management software.
Results: Plant availability increasedto96%in the first yearof operation. Wear part consumption decreasedbyan averageof18%.Customer rejections due topoor particle shape were eliminated,directly improving revenueper ton sold.

7.COMMERCIAL CONSIDERATIONS

Our pricing structurefora complete stonecrushingplantis basedon modularconfiguration tiers:

1.Basic Configuration Tier:Coversprimaryjawcrusher,vibratingfeeder,beltconveyors,andbasiccontrolsystem.Capacityguaranteedfor softto mediumhardnesslimestone.Pricedcompetitivelyforbudgetconsciousprojectsrequiringcorefunctionality.

2.Optimized Performance Tier(Recommended):Includessecondary&tertiarycrushers(coneorimpact),multideckscreening,totalfinesmanagement(dustsuppression),andfullPLCautomationwithremote monitoringcapability.Pricedasacompleteproduction solutionwithperformanceguaranteesforgraniteandbasaltapplications.

3.Customized Application Tier:Tailoredfor specificfeedmaterials(e.g.,highabrasionores),extremeclimateconditions,andfullyautomatedproductstockpilingsystems.Pricedonprojectspecificengineeringrequirements.

Optional Features:
Extendedwearpartpackages(initialset)
Onsiteoperator trainingprograms
Annualpreventivemaintenance service contracts
Telematicspackage forequipmenthealthmonitoring

Financing Options:
We workwithpartnerstooffer equipmentleasing,purchasefinancing,andrenttoownprogramstosuitvariouscapitalexpenditurestrategies.Fixedcostoperationalmaintenancepackagesareavailabletopredictablymanageongoingcosts.

8.FAQ

Q:What if my feed rock hardness changes after purchase?
A:Theplant'scrushingchambersaredesignedforadjustment.Hydraulic settingadjustmentoncone crushersallowsoperatorstocompensateformaterialvariationswithinadesignedrange tomaintainoutputandproductshape.Consultourenginersforsignificantlongtermchanges.

Q:What levelofoperatortrainingisrequired?
A:ThecentralizedPLCcontrolsystemsimplifiesoperation.We providecomprehensiveonsite trainingforyourteamcoveringnormaloperation,troubleshootingalarms,androutine maintenancecheckpoints.Mostoperatorsbecomeselfsufficientwithinoneweek.

Q:Canyouguaranteethe250300tphoutput?
A Yes,weprovideacontractualcapacityguarantee basedonmutuallyagreedfeedmaterialanalysis(laboratorytestresults)andfinalproductsizes.Thisensurestheplantmeetsyourproductivityrequirementsbeforecommissioningsignoff.

Q Howdoesthepricingcompare tobuyingindividualcomponentsandselfintegrating?
A Whiletheinitialinvestmentmayappearhigherthanapiecemealapproach,thetotalcostofownershipisoftenlower.Ourengineeredsystemeliminatescompatibilityrisksoptimizesefficiencyandreducesdowntime.Fielddatashowsintegratedplantsachieveupto20%lowercostpertonovera5yearperiodcomparedtononintegratedsolutions

Q Whatisthetypicalleadtimefromorderto commissioning?
A Forstandardconfigurationsleadtimeis1620weeksexworksincludingengineeringfabricationfactorytestingandshippingCustomconfigurationsmayrequireadditionalengineeringtime