1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare stilstand erodeer jou projekmarges? Vir aanlegbestuurders en ingenieurskontrakteurs, die vergruis- en siftingskring is dikwels die bron van kritieke knelpunte. Algemene uitdagings sluit in:
Hoë instandhoudingskoste: Gereelde laersfoute, skerm lap veranderinge, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
Ongeskeduleerde stilstand: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Ondoeltreffende materiaalvloei: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
Inkonsekwente produkgradering: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
Stygende energieverbruik: Ouer, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.

Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered vergruis- en siftingstoerusting.

2. PRODUK OORSIG

This content outlines the critical considerations for stationary and trackmounted vergruis- en siftingstoerusting, the core machinery for reducing raw feed material (bv., steengroef, herwonne beton, mineral ore) in gespesifiseerde totale groottes. The operational workflow is a continuous process:
1. Primêre groottevermindering: Large feed material is reduced by jaw or gyratory crushers.
2. Materiaal vervoer & Skulpering: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. Sekondêre/tersiêre verplettering: Cone or impact crushers further reduce material to required dimensions.
4. Finale vertoning & Sorteer: Multideck screens accurately separate crushed material into precise product fractions (bv., ¾” chip, vervaardigde sand).
5. Voorraad opgaar & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.

Application scope includes quarrying, mynbou, konstruksie & sloping herwinning, en totale produksie. Key limitations involve feed material abrasiveness (impacting wear life) en vereiste finale produkspesifikasies (dictating circuit design).

3. KERNKENMERKE

Gepatenteerde kamermeetkunde | Tegniese basis: Computermodeled kinematics and cavity profiles | Bedryfsvoordeel: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | ROI impak: Tot 12% lower costperton in abrasive applications due to extended liner life.

Modular Screen Media System | Tegniese basis: Quicktensioning wedgelock design with polyurethane damping | Bedryfsvoordeel: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | ROI impak: Reduces labor hours for maintenance by ~70% per changeout, verhoging van plant beskikbaarheid.

Gesentraliseerde smering & Toestandsmonitering | Tegniese basis: Automated lube points with flow sensors feeding a central PLC | Bedryfsvoordeel: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | ROI impak: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.

Hybrid Power Drive System | Tegniese basis: Dieselelectric configuration with onboard genset or external grid connection capability | Bedryfsvoordeel: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | ROI impak: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.

HeavyDuty Feeder with PreScreening Section | Tegniese basis: Grizzly feeder with integrated stepped grizzly bars or punch plate section | Bedryfsvoordeel: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | ROI impak: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.

Reinforced Structural Frame Design | Tegniese basis: Eindige Element Analise (FEA) optimized steel fabrication with highstress zone reinforcements | Bedryfsvoordeel: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | ROI impak: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard Norm | Ons Verplettering & Screening Solution Documented Performance | Voordeel (% Verbetering) |
| : | : | : | : |
| Crusher Liner Wear Life (Abrasive Rock) | ~450 000 ton per stel (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Langer Lewe |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (MTBF) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| Energieverbruik (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% Laer energiekoste |
| Totale koste van eienaarskap (TCO) oor 5 Years (Onderhoud + Onderdele + Stilstand)| Indexed at 100% vir vergelyking| Geskatte op 7882% of benchmark TCO| 18% aan 22% Lower TCO |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Stationary plants from 150 oor 1,200 ton per uur (TPH). Trackmounted mobile units from 200 aan 500 TPH.
Kragvereistes: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 kVA afhangende van skaal.
Materiaalspesifikasies: Vervaardig van S355JR struktuurstaal; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Mn18Cr2/Mn22Cr2).
Fisiese afmetings (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 25°C tot +45°C; dustprotected bearings (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.

6. TOEPASSINGSSCENARIO'S

Granietsteengroef Uitbreidingsprojek

Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.

Stedelike C&D Recycling Operation

Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.

7 KOMMERSIËLE OORWEGINGS

Equipment pricing tiers are structured around capacity capability:
Vlak I (600 TPH): Customengineered stationary crushing and screening plants.

Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems

Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits

Financing options are available including capital lease operating lease commercial loans tailored

8 Gereelde vrae

What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment

How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility

Wat is die tipiese deurlooptyd vanaf bestelling ingebruikneming?
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months

Verskaf jy prestasiewaarborge?
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation

What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard