1. PYNPUNT GEDREWE OPENING

Are escalating operational costs and unpredictable availability eroding your aggregate production margins? Vir aanlegbestuurders en ingenieurskontrakteurs, the core challenges of a stone crusher plant often center on three critical areas:

Ongeskeduleerde stilstand: Dra mislukkings, component wear, and unexpected breakdowns halt your entire production line. Bedryfsdata dui aan dat dit vir 'n middelgrote steengroef, elke uur se stilstand van die breker kan meer as gevolg hê $1,000 in lost revenue and idle labor.
Inkonsekwente uitset & Kwaliteit: Fluctuations in feed size or material hardness lead to variable final product gradation, failing to meet strict project specifications and resulting in rejected loads or costly reprocessing.
High Operational Expenditure: Soaring energy consumption from inefficient crushing chambers, combined with the frequent need for manual adjustment and highcost replacement parts for wear components, directly impacts your costperton metric.

Is your current crushing solution a constant source of reactive maintenance and financial leakage? What if you could implement a plant engineered from the outset for durability, doeltreffendheid, and predictable operation?

2. PRODUK OORSIG: ODM STONE CRUSHER PLANT

Our ODM Stone Crusher Plant is a stationary or semimobile crushing circuit engineered for highvolume production of aggregates (05mm, 520mm, 2040mm) from primary rock types like granite, basalt, kalksteen, en rivierklip.

Operasionele werkvloei:
1. Primêre verplettering: Dump feed is reduced by a robust jaw crusher or gyratory crusher to a manageable size (tipies <250mm).
2. Sekondêr & Tersiêre verplettering: Material is conveyed to cone crushers or impact crushers for further size reduction and shaping to meet required specifications.
3. Sifting & Klassifikasie: Vibrating screens separate crushed material into precise product fractions; oversize material is recirculated back to the appropriate crusher.
4. Materiaalhantering: A network of conveyors efficiently moves material between stages and to final stockpiles.

Toepassingsomvang & Beperkings:
Omvang: Ideal for largescale quarry operations, infrastruktuurprojekte (road/highway construction), commercial concrete batching plants, and railway ballast production requiring consistent output from 150 aan 800+ TPH.
Beperkings: Not designed for processing highly abrasive ores (bv., taconite) without specific liner configurations. Maximum feed size is determined by the primary crusher model selected.

3. KERNKENMERKE

Modulêre raamontwerp | Tegniese basis: Vooraf ontwerp, bolttogether heavyduty steel structure | Bedryfsvoordeel: Verminder werfinstallasietyd met tot 30% versus welded designs; maak voorsiening vir toekomstige herkonfigurasie of hervestiging van aanleg | ROI impak: Lower capital installation costs and preserved asset flexibility extend plant lifecycle value.

Intelligent Crushing Chamber Geometry | Tegniese basis: CADoptimized liner profiles and kinematics based on feed material analysis | Bedryfsvoordeel: Maintains consistent cavity volume throughout the wear cycle for stable output gradation and reduced frequency of manual adjustment | ROI impak: Improves product yield within spec by an estimated 812%, reducing waste.

Gesentraliseerde vetsmeerstelsel | Tegniese basis: Outomatiese, programmable lubrication unit with blockage detection | Bedryfsvoordeel: Ensures optimal bearing lubrication across all major crushers under all operating conditions; eliminates manual greasing errors and intervals | ROI impak: Field data shows a correlated 40% reduction in premature bearing failures, directly lowering parts costs and downtime.

PLCBgebaseerde prosesbeheer & Monitering | Tegniese basis: Industriële programmeerbare logikabeheerder met menslike masjien-koppelvlak (HMI) displaying amperage, druk, temperatuur | Bedryfsvoordeel: Operators can monitor plant health in realtime; automated safety interlocks prevent catastrophic damage from tramp metal or overloads | ROI impak: Enables predictive maintenance scheduling and protects major components from avoidable failure.

HighStrength AbrasionResistant Steel Components | Tegniese basis: Use of AR400/500 steel in hoppers, val, and skirting at highwear points | Bedryfsvoordeel: Significantly extends service life in highabrasion transfer zones compared to mild steel; reduces frequency of patching and replacement | ROI impak: Lowers longterm maintenance material costs and associated labor.

Tier4 Final / EU Stage V DieselElectric Option | Tegniese basis: Diesel generator set powering allelectric drives on conveyors and screens | Bedryfsvoordeel: Provides full operational mobility without reliance on grid power; meets global emissions standards for flexible deployment | ROI impak: Eliminates costly grid connection in remote sites while maintaining environmental compliance.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard Norm | Our ODM Stone Crusher Plant Solution | Gedokumenteerde voordeel |
| : | : | : | : |
| Overall Mechanical Availability (Jaarliks) | 90 92% | >95% Target Design Standard| +3% aan +5% Verbetering |
| Energieverbruik per ton verwerk (kWh/t) Varieer volgens rotstipe. Baseline = Limestone. Industry average derived from published case studies.| ~0,8 1.0 kWh/t| Optimized drive packages aim for ~0.7 0.9 kWh/t| Up to ~12% Reduction |
| Wear Life of Primary Jaw Liners (Skuur graniet) Mn18Cr2 standard castings.| ~120,000 tons| Premium Mn22Cr2 optional liners target ~150,000 tons| +25% Improvement Available |
| Gemiddelde tyd tussen mislukking (MTBF) Major Drives & Bearings Based on historical service data across comparable installations.| ~4,500 hours| Design targets >6,000 hours through superior sealing/lubrication systems.| +33% Improvement Target |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 150 TPH aan 800+ TPH nominal capacity.
Kragvereistes: Total connected load typically between 400kW 1200kW depending on configuration. Options include direct grid connection (380V/50Hz of 480V/60Hz) or integrated dieselelectric power pack.
Materiaalspesifikasies: Primary structures fabricated from Q345B steel; highwear areas utilize AR450 abrasionresistant steel liners; crusher frames are highgrade cast steel or fabricated alloy steel.
Fisiese afmetings (Voorbeeld konfigurasie): A typical threestage plant footprint may approximate 65m (L) x 45m (W) x 18m (H). Modulêre ontwerp laat aanpassing by terreinbeperkings toe.
Omgewingsbedryfsreeks: Designed for ambient temperatures from 20°C to +45°C with optional coldweather or dustsuppression packages available.

6. TOEPASSINGSSCENARIO'S

Highway Construction Project – Remote Location

Uitdaging: A contractor needed consistent Class I & II aggregates for a new highway section with no local grid power access. High mobilization/demobilization speed was critical due to tight project timelines.
Oplossing: Implementation of a semimobile ODM Stone Crusher Plant with integrated Tier4 Final diesel power pack and three crushing stages.
Resultate: The plant was commissioned within one week of arrival on site. It achieved an average output of 320 TPH meeting all gradation specs without reliance on external utilities.

Kommersiële uitbreiding van granietsteengroef

Uitdaging: An existing quarry faced declining product quality consistency due to an aging secondary/tertiary circuit leading to excessive recirculating load (~40%) energy waste.
Oplossing: Replacement of the old tertiary cone crushers with new models featuring intelligent chamber geometry within an optimized ODM circuit layout.
Resultate: Recirculating load decreased to approximately 28%. This improved net throughput by 15% while reducing specific energy consumption by an estimated 9%, enhancing overall margin per ton processed.

7 KOMMERSIËLE OORWEGINGS

Our ODM Stone Crusher Plants are offered under clear commercial frameworks:

Prysvlakke: Pricing scales according to capacity throughput design complexity:
Tier I Basic Configuration Standard duty primary jaw secondary cone basic screening
Tier II Enhanced Configuration Heavy duty primary premium cone multi stage screening dust suppression
Tier III Custom Turnkey Solution Full electrical automation remote monitoring advanced environmental controls

Optional Features Premium wear liners automatic level sensors magnetic separators sound attenuation enclosures extended walkways service platforms

Dienspakkette beskikbaar:
Basic Warranty Coverage standard parts labor warranty period
Annual Maintenance Contract scheduled inspections preventive maintenance parts discounts
Full Service Agreement includes guaranteed availability performance metrics consumables management

Financing Options We work with international export credit agencies equipment finance partners offer competitive leasing rental purchase structures suit project cash flow requirements

8 Gereelde vrae

Q What level foundation preparation required?
A Detailed civil engineering drawings provided require stable compacted ground minimal concrete foundations modular design reduces concrete volume versus traditional plants

Q How does ensure compatibility existing equipment?
A Our engineering team conducts pre sale review proposed layout feed characteristics can adapt transfer points conveyor lengths integrate certain existing units like primary screens

V Watter tipiese lewering tyd aflewering ingebruikneming?
A For standard configurations lead time ranges months ex works Site commissioning supervised our engineers typically requires weeks depending complexity includes operator training

Q Are spare parts readily available internationally?
A We maintain global network certified warehouse partners provide genuine spare parts support Critical wear items commonly stocked ensure minimal logistics delay

Q Can operate extreme cold climates?
A Yes optional packages include heated lube oil systems cold start battery packages insulated piping enclosures critical components ensure reliable operation sub zero temperatures

Q What process guarantee product gradation?
A While final gradation depends feed material characteristics we provide performance guarantees overall throughput mechanical availability based agreed test protocols commissioning

Q Do offer financing large capital purchases?
A Yes we have established relationships several international finance institutions assist structuring purchase lease arrangements improve project economics