1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that erode profitability? The challenges of a 250300tph stone crushing plant are significant: unpredictable throughput fluctuations leading to missed delivery schedules, excessive wear part costs from inefficient crushing actions, and high energy consumption per ton of finished product. Downtime for maintenance or unplanned repairs can cost thousands per hour in lost production and idle labor. Are you questioning how to achieve consistent, specified output without constant oversight? Is your current plant configuration failing to adapt to varying feed material hardness? The solution lies not in pushing machinery harder, but in deploying an intelligently engineered 250300tph stationary crushing and screening plant designed for sustained, costeffective operation.

2. PRODUCT OVERVIEW

This solution is a complete stationary crushing and screening plant engineered for a nominal output range of 250 to 300 metric tons per hour (tph) of finished aggregate. It is configured for primary, secondary, and tertiary crushing stages to produce up to 5 calibrated product sizes from hard rock (granite, basalt) and abrasive materials.

Operational Workflow:
1. Primary Reduction: Large feed material (up to 750mm) is consistently fed into a robust primary jaw crusher for initial size reduction.
2. Secondary Crushing & Screening: Crushed material is conveyed to a secondary cone crusher for further reduction. A primary screen separates sized material, routing oversize back for recrushing.
3. Tertiary Shaping & Final Sizing: For highspecification products like chippings or manufactured sand, a tertiary impact crusher or vertical shaft impactor (VSI) provides final shaping. Subsequent screening decks ensure precise gradation control.

Application Scope & Limitations:
Scope: Ideal for large quarry operations, major infrastructure projects requiring onsite aggregate production, and dedicated aggregate supply yards serving regional markets.
Limitations: Requires stable, prepared feed material; not designed for mobile or semimobile applications without significant modification. Site requires adequate foundation engineering and space for the plant footprint and stockpiling.

3. CORE FEATURES

Intelligent Feed Control System | Technical Basis: Multipoint level sensors and variablefrequency drive (VFD) coordination | Operational Benefit: Maintains optimal cavity level in all crushers, preventing choke feeding or empty running | ROI Impact: Reduces liner wear by up to 15% and improves energy efficiency by ensuring consistent load.
HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Highstrength steel construction with adjustable grizzly bars | Operational Benefit: Removes fines prior to primary crushing and ensures steady, regulated feed | ROI Impact: Increases primary crusher capacity by up to 20% and reduces wear on the primary chamber.
Centralized Greasing & PLC Automation | Technical Basis: Automated lubrication circuits with programmable logic controller (PLC) monitoring | Operational Benefit: Ensures critical bearings receive precise lubrication intervals without manual intervention | ROI Impact: Extends bearing service life by an average of 30% and minimizes lubricationrelated failures.
Modular Conveyor System with Impact Zones | Technical Basis: Reinforced conveyor design with rubberlined impact beds at transfer points | Operational Benefit: Dramatically reduces belt wear and spillage at highimpact loading areas | ROI Impact: Lowers belt replacement costs by approximately 25% annually.
Hybrid Power Configuration Option | Technical Basis: Plant sections can be configured for grid connection or diesel generator sets | Operational Benefit: Provides operational flexibility in areas with unstable grid power or for phased commissioning | ROI Impact: Eliminates fullsite power downtime; allows continuous operation during grid maintenance.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This 250300tph Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tons per Hour (Avg.)| 275 tph with ±15% variance | Sustained 285 tph with ±5% variance| +3.6% output with 67% better consistency |
| Power Consumption| ~0.9 kWh/ton processed| ~0.82 kWh/ton processed| ~9% reduction in energy cost per ton |
| Liner Wear Life (Primary)| Based on abrasive granite feed| Based on same abrasive granite feed| +1520% extended service life |
| Mean Time Between Failure (MTBF)| Major components ~1,200 hours| Major components ~1,500 hours| +25% improvement in reliability |

5. TECHNICAL SPECIFICATIONS

Nominal Capacity: 250 300 tph (varies based on feed material hardness and product gradation).
Primary Crusher: Jaw Crusher Model JCE1303 / Feed Opening: 1300mm x 300mm / Max Feed Size: ≤750mm.
Secondary Crusher: MultiCylinder Hydraulic Cone Crusher / Chamber Options Available.
Tertiary Crusher: Vertical Shaft Impactor (VSI) or Horizontal Shaft Impactor (HSI) options.
Screening Units: Tripledeck heavyduty vibrating screens; Total Screening Area ≥15m².
Power Requirement: Total installed power approximately 550 650 kW; configured for 380V/50Hz/3Ph or customizable.
Key Material Specifications: High manganese steel crusher liners; DIN standard conveyor idlers; PLC from industrialgrade supplier.
Physical Dimensions (Approx.): Length ~85m x Width ~25m x Height ~12m (varies with layout).
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dust suppression system compliant with standard regulations.

6. APPLICATION SCENARIOS

Highway Construction Project Aggregate Supply

Challenge: A contractor needed guaranteed daily output of 280tph of base course and subbase aggregates within strict particle shape specifications to meet accelerated roadbuilding schedules.
Solution: Implementation of this turnkey stationary crushing plant featuring a secondary cone crusher for cubicity and a tertiary VSI for final shaping control.
Results: The plant exceeded target output at a consistent average of over the project duration while producing aggregates that met all engineering specifications without reprocessing.

Granite Quarry Expansion

Challenge: An existing quarry operation’s older plant could not reliably exceed production rates required expansion into new markets due to frequent breakdowns .
Solution Replacement with this new configured specifically . The intelligent feed system was calibrated .
Results Field data shows overall equipment effectiveness improved by plant now operates two additional shifts monthly .

7 COMMERCIAL CONSIDERATIONS

Pricing is structured around core configuration tiers:
• Tier A Base Plant Includes primary secondary crushing basic screening essential conveyors
• Tier B High Specification Adds tertiary VSI advanced PLC automation upgraded dust control
• Tier C Turnkey Package Includes civil engineering design foundation drawings erection supervision commissioning

Optional Features Premium wear part packages extended warranty remote monitoring diagnostics

Service Packages Annual maintenance contracts parts supply agreements technical training programs

Financing Options Available through partner institutions including lease purchase structures project financing tailored capital expenditure cycles

8 FAQ

Q What are the main civil works required before installation
A A level compacted site capable of supporting load bearing pressures detailed foundation drawings are provided Pile foundations may be necessary based on local soil conditions

Q How does this plant handle variations in rock hardness
A The hydraulic adjustment systems on the cone crushers allow operators settings compensate changes maintaining consistent product size distribution

Q What is the typical lead time from order commissioning
A For standard configurations lead time ranges months depending complexity Customizations may extend this period Detailed project schedules are provided upon inquiry

Q Are your plants compatible existing equipment conveyors screens
A Integration possible requires detailed review existing layouts transfer points electrical systems Engineering assessment recommended

Q What operator skill level required run this plant effectively
A The PLC automation simplifies routine operation Training is provided covering basic controls troubleshooting Maintenance personnel require mechanical electrical competencies

Q Can production be scaled beyond tph future
A The base design incorporates headroom key components like feeders conveyors Upgrading certain elements like increasing screen area installing higher capacity tertiary stage can increase output