1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare stilstand erodeer jou projekmarges? Vir aanlegbestuurders en kontrakteurs, the crushing and screening circuit is often the bottleneck where profit is won or lost. Algemene uitdagings sluit in:
Ongeskeduleerde stilstand: Component failures in critical crushers or screeners halt entire production lines, duisende per uur in verlore uitset en arbeid kos.
Hoë instandhoudingskoste: Frequent wear part replacement and extensive manual adjustments consume both budget and skilled technician hours.
Inkonsekwente produkkwaliteit: Inefficient screening and improper crushing lead to offspec aggregate, produkverwerping tot gevolg het, herverwerkingskoste, en klanteverhoudings beskadig.
Energie ondoeltreffendheid: Ouer, nonoptimized equipment consumes excessive power per ton of material processed, 'n direkte impak op jou winspunt.
Rigiede konfigurasie: Fixed plants cannot adapt to changing feed material or final product requirements, limiting operational flexibility and contract opportunities.

What if your primary crushing station and screening deck could deliver not just throughput, maar voorspelbare prestasie, laer koste perton, and the agility to meet shifting market demands?

2. PRODUK OORSIG

This product line encompasses a range of premium stationary and semistationary crushing and screening plants engineered for highvolume aggregate production, mynvoorverplettering, en konstruksie & sloping herwinning. The operational workflow is designed for continuous, efficient material processing:

1. Primêre voeding & Verpletterend: Dump trucks feed material into a rugged vibrating grizzly feeder which removes fines and directs oversize to a highcapacity jaw or gyratory crusher for initial size reduction.
2. Intermediate Conveying & Verpletterend: Crushed material is conveyed to secondary cone or impact crushers for further refinement, with metal detectors and tramp iron relief systems protecting downstream components.
3. Voorafskerm & Klassifikasie: Material may be routed through a scalping screen before secondary crushing to improve efficiency.
4. Finale vertoning & Voorraad opgaar: The crushed aggregate is classified into precise specifications by multideck vibrating screens, with conveyors directing sorted material to designated stockpiles.

Toepassingsomvang: Ideaal vir grootskaalse steengroef, hard rock mining primary circuits, en groot infrastruktuurprojekte wat konsekwent vereis, highquality aggregates (040mm+). Limitations include suitability primarily for fixed or semifixed installation sites; highly mobile contract crushing requires dedicated portable equipment.

3. KERNKENMERKE

Hydroset CSS-aanpassing | Tegniese basis: Hidrouliese suier wat die hoofas ondersteun | Bedryfsvoordeel: Geslote instelling (CSS) can be adjusted safely in under 60 sekondes sonder om die breker te stop, enabling rapid response to product gradation changes. | ROI impak: Eliminates hours of manual shim adjustment downtime per change, increasing plant utilization by up to 7% jaarliks.

Modulêre skermmediastelsel | Tegniese basis: Interlocking polyurethane or rubber panels with tensioning rails | Bedryfsvoordeel: Panels can be replaced by a twoperson crew in under 30 minutes per deck without specialized tools. | ROI impak: Reduces screen deck maintenance downtime by over 50% compared to traditional woven wire cloth systems.

PLCB-gebaseerde aanlegoutomatisering | Tegniese basis: Gesentraliseerde programmeerbare logiese beheerder met aanraakskerm HMI | Bedryfsvoordeel: Monitors amp draw, laer temperature, en voertempo's; automatically regulates feeder speed and triggers alarms for preventative intervention. | ROI impak: Voorkom katastrofiese mislukkings; velddata toon 'n tipiese 1520% vermindering in onbeplande onderbrekings.

Direct Drive Crusher Tegnologie | Tegniese basis: Crusher coupled directly to motor via Vbelts without gearboxes | Bedryfsvoordeel: Hoër kragoordragdoeltreffendheid (oor 95%) and reduced mechanical complexity. | ROI impak: Lowers energy consumption by up to 10% versus indirect drives and reduces potential failure points.

Vlak 4 Finale / EU Stage V Power Unit Integration | Tegniese basis: Factoryintegrated, emissionscompliant diesel gensets or electric motor drives with soft starters | Bedryfsvoordeel: Provides compliant power flexibility for remote sites or grids with limited capacity; soft starters reduce electrical network stress. | ROI impak: Simplifies permitting; reduces peak current demand charges on electric installations.

Reinforced BoxSection Conveyor Frames | Tegniese basis: Highstrength welded steel construction with internal stiffeners | Bedryfsvoordeel: Withstands continuous heavyimpact loading without frame deflection or misalignment. | ROI impak: Extends conveyor belt life by maintaining proper tracking; reduces structural maintenance over the plant's lifetime.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard Norm | Ons Verplettering & Siftingsoplossing Gedokumenteerde voordeel |
| : | : | : |
| Ton per uur (TPH) Beskikbaarheid | 8588% availability over a quarter >90% availability over a quarter +35% verbetering |
| KostePerTon (Dra onderdele) USD $0.45 $0.55/ton processed USD $0.38 $0.42/ton processed Up to 20% vermindering |
| Energieverbruik (kWh/ton) ~0,85 1.1 kWh/ton ~0.75 0.95 kWh/ton Up to 15% verbetering |
| Skerm Media Verander Tyd (per deck) ~90 120 minute <30 minutes Over 60% vinniger |
| CSS-aanpassingstyd (Kegelbreker) ~60 90 minute <2 minutes Over 95% vinniger |

_Availability defined as (Scheduled Operating Time Unscheduled Downtime) / Scheduled Operating Time._

5.TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 400 TPH tot verby 1,500 TPH finale produk uitset.
Primêre Crusher Opsies: Kaakbrekers (1,200mm x 830mm voeropening) of Primêre Giratory Brekers (54” model).
Sekondêre/Tersiêre Brekers: Hewige kegelbrekers met veelvuldige kameropsies.
Siftingseenhede: Highenergy tripledeck vibrating screens (up to 8m² screening area per deck).
Kragvereistes: Full plant electric configuration typically requires a mains supply of 800kVA – 2MVA; integrated diesel genset options available.
Sleutel materiaal spesifikasies: Manganese steel crusher jaws/liners (18% Mn); Hardox®-voerings in hoppers en geute; SKF/FAG class bearings throughout.
Fisiese afmetings (Tipiese plantvoetspoor): Approximately L70m x W25m x H15m (verskil aansienlik met konfigurasie).
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 25°C tot +45°C; dust suppression system compliant with <10mg/m³ emissiestandaarde.

6. TOEPASSINGSSCENARIO'S

Granietsteengroef Uitbreidingsprojek

Uitdaging 'n Steengroef wat nodig is om produksie van spoorwegballas te verhoog (40mm+20mm) deur 40% but faced space constraints preventing simple line duplication.
Solution Implementation of a singletrack mounted primary jaw crushing station feeding a dualprocess circuit with secondary cone crushers dedicated to different final products.
Results Achieved target throughput increase within the existing footprint; automated controls allowed quick switching between ballast production and aggregate chips (20mm), improving contract flexibility.

Stedelike C&D Recycling Facility Upgrade

Challenge A recycling center processing concrete demolition waste experienced excessive wear from rebar contamination and inconsistent final product due to fluctuating feed composition.
Solution Installation of a heavyduty impact crusher with hydraulic apron adjustment for primary reduction paired with an aggressive doubledeck scalping screen fitted with abrasionresistant media.
Results Tramp metal removal efficiency improved by over 80%; consistent final aggregate quality met strict city specification for road base materials; wear part life increased by an average of 35%.

7. KOMMERSIËLE OORWEGINGS

Our luxury crushing equipment is positioned as a capital investment focused on longterm total cost of ownership reduction.

Pricing tiers are structured around core plant configuration:
Tier A Base Stationary Plant includes primary crusher feeder module basic screening tower stockpile conveyors starting at approximately USD $2 miljoen
Tier B Advanced Automated Plant includes all Tier A features plus secondary/tertiary crushing modules PLC automation system advanced dust suppression
Tier C Custom Turnkey Solution fully engineered sitespecific solution including civil works design installation commissioning training

Optional Features Premium ceramic wear liners for highly abrasive applications remote monitoring telemetry package sound attenuation enclosures

Service Packages Annual Platinum Coverage comprehensive parts labor scheduled inspections Gold Coverage partsonly coverage with discounted labor rates

Financing Options Available through partnered financial institutions including operating leases capital leases longterm rentaltoown structures typically structured over 5year terms

8. Gereelde vrae

Q What level of ground preparation is required for installation
A These are substantial permanent structures requiring professional civil engineering foundation design typically involving reinforced concrete piers footings Proper site preparation is critical for longterm alignment stability

Q How does this equipment integrate with our existing conveying system
A Our engineering team can design custom transfer chutes control system interfaces provided we receive detailed drawings of your current conveyor specifications Belt widths speeds heights must be matched

Q What is the expected operational lifespan of the main crusher frame
A With proper maintenance excluding wearable liners the main crusher body frames are designed for a minimum service life exceeding 25 years based on finite element analysis fatigue testing

Q Are operators provided training on the new control system
A Yes comprehensive onsite training for both operators maintenance technicians is included as standard during commissioning covering daily operation troubleshooting basic maintenance procedures

Q Can we source common wear parts like screen cloths locally
A While we recommend genuine parts for optimal performance our modular screen system uses standardized panel sizes that can accommodate certain thirdparty media Basic Vbelts bearings are also industrystandard items