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 represents a critical production tier, yet common operational challenges can significantly undermine its return on investment.

Inconsistent Throughput & Downtime: Unplanned stoppages due to feeder blockages, crusher overloads, or conveyor misalignment can cost thousands per hour in lost production and idle labor.
High Operational & Maintenance Costs: Are you constantly budgeting for premature wear part replacement, excessive energy consumption from inefficient crushing chambers, or unscheduled maintenance labor?
Product Quality Variability: Fluctuations in final product gradation and excessive flakiness can lead to rejected loads, contract penalties, and damage to your market reputation.
Scalability & Flexibility Limitations: Can your current setup efficiently handle variations in feed material hardness (from limestone to granite) or quickly adapt to changes in required product specs without major reconfiguration?

The central question is: how do you achieve reliable, costperton production within the 250300tph range while maintaining product integrity and controlling operational expenses?

2. PRODUCT OVERVIEW

This solution is a stationary 250300 ton per hour (tph) hard rock crushing and screening plant designed for highvolume aggregate production. Engineered as a complete circuit, it transforms large feed material into precisely graded commercial aggregates.

Operational Workflow:
1. Primary Reduction: Large quarryrun rock (up to 750mm) is consistently fed into a robust primary jaw crusher for initial size reduction.
2. Secondary & Tertiary Crushing: The output is conveyed to secondary cone crushers for further reduction, with optional tertiary crushers or impactors for shaping and fine crushing.
3. Material Screening: Multipledeck vibrating screens accurately separate crushed material into specified size fractions (e.g., 05mm, 510mm, 1020mm).
4. Stockpiling & Recirculation: Onspec material is conveyed to designated stockpiles. Oversize material is automatically recirculated back into the circuit for recrushing, ensuring efficiency.

Application Scope: Ideal for producing aggregates for road base, concrete asphalt, railway ballast, and construction projects requiring highvolume, specificationgrade material.

Limitations: This plant configuration is designed as a stationary or semistationary installation. It requires proper foundational support and is intended for mediumtohard abrasives (compressive strength <350MPa). For fully mobile applications or processing softer materials like clayrich rock without prescalping, alternative configurations may be recommended.

3. CORE FEATURES

HighCapacity Primary Jaw Crusher | Technical Basis: Optimized kinematics & heavyduty roller bearing design | Operational Benefit: Handles peak feed loads with reduced stress cycles, minimizing risk of stall or fatigue failure | ROI Impact: Field data shows up to 15% lower downtime risk versus standard designs, protecting revenue flow.

Intelligent Crushing Chamber Automation | Technical Basis: Hydropneumatic tramp release and clearing system with PLCcontrolled setting adjustment | Operational Benefit: Automatically handles uncrushables and allows remote adjustment of crusher settings for product size changes | ROI Impact: Reduces unplanned interventions by up to 80% and enables faster product changeovers, increasing plant utilization.

MultiStage Precision Screening System | Technical Basis: HighGforce linear motion screens with modular tensioned screen decks | Operational Benefit: Delivers sharp separations even under high feed rates and damp conditions; decks are replaceable individually | ROI Impact: Improves final product yield accuracy by an estimated 812%, reducing waste and maximizing saleable tonnage.

Centralized Process Control & Monitoring | Technical Basis: SCADAbased control panel with motor current monitoring, chute blockage detection, and wear part tracking | Operational Benefit: Your operators manage the entire flow from a single station with realtime alerts on performance deviations | ROI Impact: Enables predictive maintenance scheduling and reduces troubleshooting time by approximately 30%, optimizing labor efficiency.

HeavyDuty Conveyor System with Impact Zones | Technical Basis: Channel frame construction with impact idlers at loading points and abrasionresistant belting | Operational Benefit: Withstands continuous hightonnage operation with minimal belt stretch or damage at transfer points | ROI Impact: Extends belt service life by an average of 25%, directly lowering consumable costs per ton produced.

Modular Electrical System Design | Technical Basis: IPrated motor control centers (MCCs) with standardized connections and clear cable routing | Operational Benefit: Simplifies installation onsite and allows for easier future expansion or component replacement during service | ROI Impact: Can reduce initial installation electrical labor costs by approximately 15% compared to nonmodular systems.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 250300tph Plants | This Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime | ~8588% (including planned maintenance) |>92% Target Availability| +47% More Production Time |
| Energy Efficiency (kWh/ton)| Varies widely; baseline set at 100%| Industry testing demonstrates ~95% of baseline consumption| ~5% Reduction in Power Cost |
| Wear Part Cost per Ton| Cost index = 100% (for abrasive granite)| Cost index = ~87% via optimized alloys & chamber designs| ~13% Lower Consumable Cost |
| Average Setup / Commissioning Time| 810 Weeks (foundation to first crush)| Target: 68 Weeks with modular design| Up to 25% Faster Deployment |
| Footprint Efficiency (Tons/hr/m²)| Baseline = 100%| Compact flow design achieves ~115% of baseline| ~15% Better Space Utilization |

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 250 300 metric tons per hour (tph), depending on feed material hardness (<350 MPa compressive strength) and required product gradation.
Primary Power Requirement: Approx. 550 650 kW total connected load. Typical supply: 400V/50Hz or customized voltage/frequency.
Key Material Specifications:
Primary Crusher Jaw Plates / Cone Liners: Manganese steel alloy (Mn18Cr2/Mn22Cr2).
Screen Decks: Highcarbon steel wire mesh or polyurethane panels.
Main Frame Structure: Fabricated from S355JR grade steel.
Conveyor Belting: EP630/3 minimum ply rating with abrasionresistant top cover.
Approximate Physical Dimensions (L x W x H): Varies by layout; typical compact arrangement fits within ~65m L x 28m W x 15m H envelope.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system included; enclosures available for extreme weather operation.

6. APPLICATION SCENARIOS

Highway Construction Project Supply

Challenge A contractor needed a guaranteed supply of over 500,000 tons of multiple aggregate specifications within an18month window from a variable hardness granite quarry.
Solution Implementation of this configured plant solution featuring primary jaw crushing followed by two secondary cone crushers feeding a tripledeck screening system.
Results The plant achieved an average sustained output of280 tph at the required specifications.Availability exceeded91%, enabling the project supply contract to be fulfilled4 weeks ahead of schedule.

Commercial Aggregate Producer Expansion

Challenge An established producer sought to expand into the premium concrete aggregate market but their existing plant produced excessive flaky particles.
Solution Integration of this solution configured with a shaping tertiary impact crusher stage after primary/secondary crushing,and highprecision screens.
Results Product cubeicity improved significantly,fines production was better controlled,and the producer captured new contracts at apremium price point.Plant flexibility allowed quick switching between asphaltand concrete spec materials.

7. COMMERCIAL CONSIDERATIONS

Our approach provides clarity in investment planning:

Pricing Tiers: We offer three core configurations:
Tier A (Essential Performance) – Core crushing/screening circuit meeting250 tph spec on standard materials.Lower initial capex focus.
Tier B (Optimized Production) – Enhanced features including automation,intelligent controls,and superior wear components.Recommended configuration formost hard rock applications up to300 tph.Best balanceof capexand lifetimeoperating cost(LTOC).
Tier C (Maximum Uptime) – Includes full environmental enclosures,belt scales,predictive monitoring sensors,and premium component packages.Designedfor operations wheremaximizing runtimeis critical despite higher initial investment

Optional Features: Dust extraction systems,washing attachments,belt scales,magnetic separators,customized walkways/service platforms

Service Packages: Choose from annual inspection plans,wear part kitswith guaranteed pricing,inventory management programs,and remote diagnostics support

Financing Options Available through partner institutions including equipment leasing,tailored loan structures,and renttoown programs subjectto credit approval

FAQ

Q1 Is this plant compatible with our existing primary feeding systemand stockpile conveyors?
A Yes.The plantis designedwith standardized interface heightsand conveyor speeds.Engineering specifications are provided upfrontto ensure compatibilitywith your site's specific feed hopperand downstreaminfrastructure

Q2 Whatisthe expected lead timefrom orderto commissioning?
A For standard configurationslead times typically range between20and28 weeksdependingon complexityFinal site commissioningrequiresapproximately2weekswith oursupervision subjectto site readiness

Q3 How does thisplant manage fluctuationsin feedmaterial hardness?
A Thecrushing chambersare designedfor awide reductionratioandthe control systemmonitors motorloadautomatically adjustingfeedratesvia theprefeeder tomaintain optimal throughputand protectthecrushersfrom overload

Q4 Whatisthe typical manpowerrequirementto operatethisplant?
A The centralizedcontrolsystemallows forefficientoperationbyonecontrolroomoperatorper shiftOneadditional groundpatrolpersonnelisrecommendedfor visual inspectionsTotal directlaboris typicallytwo personsper shift

Q5 Arewearparts readilyavailableand whatarethe expectedconsumptioncosts?
A We maintainaglobal inventoryofcriticalwearpartsConsumptioncostsarequotedonapertontreatedbasisbasedonyour specificfeedmaterialanalysiswith mosthardrockapplicationsfallingwithinapredictablerangeGuaranteed pricingprogramsareavailable

Q6 Do youprovide trainingfor ourmaintenance crew?
A YesComprehensive trainingfor bothoperatorsandmaintenance techniciansisprovidedduringcommissioningThisincludeshandson instructionaswellasdetailedmanualsandschematicaccess

Q7 Canthisplantbedesignedfor futurecapacityexpansionbeyond300tph?
A Themodulardesignofthestructural supports electricalinfrastructureandconveyor systemsfacilitatesfutureexpansionEngineeringconsultationisrecommendedduringtheinitialplantlayoutphaseto planforsuch scalability