1. PYNPUNT GEDREWE OPENING

Managing a stone quarry crushing plant presents persistent operational and financial challenges. Stry jy met:
Oormatige stilstand: Unplanned stoppages for liner changes, blokkasies, or mechanical failures, kos duisende per uur in verlore produksie en ledige arbeid.
Inkonsekwente produkopbrengs: Poorly calibrated or worn crushing stages producing offspec aggregate, die vermindering van premium produk opbrengs en dwing herverplettering.
Spiraling Maintenance Costs: Frequent replacement of highwear components like mantles, konkaaf, en kakebeenplate, coupled with high labor hours for servicing.
Hoë energie-intensiteit: Inefficient crushing chambers and drives that consume excessive power per ton of processed material, winsmarges direk erodeer.
Onbuigsame konfigurasie: A plant that cannot be easily adjusted to meet changing market demands for different aggregate sizes or volumes.

If these issues sound familiar, the efficiency of your entire operation hinges on the core of your process: the primary crushing station. The right ODM stone quarry crushing plant solution must address these points directly with proven engineering.

2. PRODUK OORSIG

Hierdie produk is 'n swaardiens, stationary primary jaw crusher plant, engineered as the first reduction stage in a hard rock quarry operation. It is designed to receive blasted feed from haul trucks and reduce large boulders (tot 1200 mm) to manageable sizes for secondary crushing.

Operasionele werkvloei:
1. Voerinname: Dump trucks deposit shot rock into a rugged steel apron feeder.
2. Primêre verplettering: The apron feeder conveys material at a controlled rate into the jaw crusher, where compressive force breaks the rock.
3. Primêre sifting & Bypass: A grizzly section ahead of the crusher removes natural fines, while an integrated bypass chute handles oversize or uncrushable material.
4. Produkvervoer: Crushed product is discharged onto a main conveyor belt for transport to the next stage of the processing circuit.

Toepassingsomvang & Beperkings:
Omvang: Ideal for hightonnage production of granite, basalt, kalksteen, en ander skuur aggregate. Suited for permanent installation in largescale commercial quarries.
Beperkings: Not designed for portable applications, very sticky or claybound materials without preprocessing, or as a standalone finishing plant without secondary/tertiary stages.

3. KERNKENMERKE

Diep verpletterende kamer & Geoptimaliseerde kinematika | Tegniese basis: Verhoogde kneephoek en langer drukslag | Bedryfsvoordeel: Higher volume reduction per cycle, reducing cycle count and wear | ROI impak: Tot 15% higher throughput capacity within the same footprint

Hidrouliese skakelaar & Aanpassingstelsel | Tegniese basis: Vervangbare hidrouliese silinder vir spanning en skoonmaak | Bedryfsvoordeel: Enables quick clearing of tramp metal and chamber blockages in minutes vs. ure; allows safe CSS adjustment under load | ROI impak: Reduces downtime events by an average of 80% for chamberrelated stoppages

QuarryGrade HeavyDuty Frame | Tegniese basis: Fabricated steel plate design with reinforced stress points and finite element analysis (FEA) validering | Bedryfsvoordeel: Withstands continuous highimpact loading and cyclic stress without frame fatigue or cracking | ROI impak: Elimineer risiko van katastrofiese raamversaking, die operasionele lewe verder verleng 20 jare

Geïntegreerde motorbasis & Drive Bewaking | Tegniese basis: Unified baseplate for crusher and motor with full perimeter guarding | Bedryfsvoordeel: Simplifies alignment during installation; provides inherent safety compliance; reduces installation time by approximately 30% | ROI impak: Lowers total installed cost and ensures immediate operational safety compliance

WedgeBased Jaw Plate Retention System | Tegniese basis: Mechanical wedge lock system secures jaw plates without backing resin | Bedryfsvoordeel: Allows fast replacement of jaw liners; typically completed in under 4 hours by a standard maintenance crew | ROI impak: Increases plant availability and reduces labor costs associated with liner maintenance

Gesentraliseerde outomatiese smeerstelsel | Tegniese basis: Programmable lubrication unit serving all key crusher bearings | Bedryfsvoordeel: Ensures consistent, correct lubrication intervals without operator intervention; provides fault alerts for flow issues | ROI impak: Verleng die dienslewe van die laer met tot 40%, preventing costly unscheduled bearing failures

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Gemiddeld) | This Primary Crushing Plant Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Beskikbaarheid (Geskeduleerde looptyd) | 9294% | 9698%+ | +46% |
| Liner Change Time (Kaakplate) | 68 ure (bemanning afhanklik) | 3,200 ure| +60% |

5. TEGNIESE SPESIFIKASIES

Model Aanwysing: PEV145
Voer opening: 1400mm x 1100 mm
Maksimum voergrootte: 1200mm
Geslote kant-instelling (CSS) Reeks: 150mm 280 mm
Kapasiteitsreeks (Wissel volgens materiaal & CSS): 450 850 MTPH
Dryfkragvereiste: 200 kW (250 HP) Electric Motor
Breker gewig (excluding feeder & vervoerband): ~62 000 kg
Total Plant Footprint (LxW): Ongeveer. 18m x 8m
Raammateriaal: ASTM A36 Steel Plate (>50mm thick at critical points)
Jaw Plate Material: Mn18Cr2 / TIC Insert Hybrid Alloy
Bedryfstemperatuurreeks: 30°C tot +45°C
Stofvrystellingbeheer: Prepared for direct connection to dry fog or baghouse system.

6. TOEPASSINGSSCENARIO'S

Granite Quarry Expansion Project in Southeast Asia

Uitdaging: An existing quarry needed to double output but had space constraints for new primary crushing infrastructure. The existing plant suffered from low throughput and daily blockages.
Oplossing: Implementation of a single highcapacity PEV145 primary jaw crusher plant with an optimized deepchamber design and hydraulic toggle system replaced two older units.
Resultate: Behaal a 120% increase in primary circuit throughput within a similar footprint. Blockagerelated downtime decreased from an average of 10 hours/week to under 1 hour/week.

HighAbrasion Basalt Operation in North America

Uitdaging: Extremely abrasive basalt was causing jaw plate wear costs to become prohibitive at over $0.12 per ton verwerk.
Oplossing: Deployment of this crushing plant equipped with proprietary TIC insert hybrid jaw plates and a centralized automated greasing system.
Resultate: Field data shows jaw liner life increased by approximately 70%, reducing wear cost per ton to under $0.07. Consistent automated lubrication contributed to zero bearingrelated failures in the first two years of operation.

7. KOMMERSIËLE OORWEGINGS

The capital investment for a complete primary crushing station is significant but defined by clear tiers based on configuration:

Basistoerustingvlak ($XXXk $XXXk): Includes core jaw crusher on motor base apron feeder grizzly section discharge conveyor walkways ladders basic guarding electrical control panel with motor starters.

Opsionele kenmerke:
Onboard dust suppression spray system (+$XXk)
Advanced PLC automation package with remote monitoring (+$XXk)
Heavyduty skid foundation vs concrete foundation (+$XXk)
Spare parts starter kit liners toggle seats bearings (+$XXk)

Dienspakkette:
1.Preventive Maintenance Plan scheduled inspections parts discounts technical support.)
2.Comprehensive Lifecycle Contract includes all planned maintenance wear parts replacements fixed annual fee.)

Financing Options are available through our partners including equipment leasing capital loans payperton agreements structured over terms.

FAQ-afdeling

Q1 Is this primary crushing plant compatible with my existing secondary cone crushers conveyors?
A1 Yes industrystandard discharge heights belt widths are accommodated Our engineering team will review your downstream equipment specifications ensure seamless integration into your current flow.

Q2 What is the expected impact on my overall plant energy consumption?
A2 Field data from comparable installations shows total energy consumption per ton can decrease between due higher throughput efficiency reduced recirculating load from better primary reduction Consult our team sitespecific analysis.

Q3 How does your pricing compare building customdesigned solution?
A3 As ODM manufacturer we offer significant cost advantages over fully custom engineered designs while maintaining applicationspecific performance Standardized modular design reduces manufacturing lead times typically delivering within weeks not months.

Q4 What are typical installation commissioning requirements?
A4 We provide detailed foundation drawings general arrangement diagrams comprehensive commissioning checklist Our team can supervise installation startup ensure optimal performance training provided your operations maintenance staff included purchase agreement.

Q5 What warranty coverage provided?
A5 We offer standard months warranty defects materials workmanship Extended warranty packages major components structures available purchase Warranty terms clearly outlined commercial proposal documentation.

Q6 Can you supply complete processing plant just primary stage?
A6 While we specialize primary secondary crushing solutions we act main contractor partner network reputable suppliers screens conveyors washing systems deliver turnkey project scope required Your project manager will coordinate all aspects single point contact simplify procurement process you