1. PYNPUNT GEDREWE OPENING

Are you managing a midtolarge scale aggregate operation and facing persistent bottlenecks that erode profitability? Vir aanlegbestuurders en ingenieurskontrakteurs, die 250300 TPH capacity range is critical, yet often problematic. Algemene uitdagings sluit in:
Inkonsekwente deurset: Feed material variability causing output to fluctuate below the 250 TPH target, failing to meet project batching schedules and leading to costly penalties.
High PerTon Operating Costs: Premature wear on crusher liners and screens, combined with inefficient power distribution across multiple units, driving maintenance and energy expenses higher than budgeted.
Oormatige stilstand vir instandhouding: Poorly coordinated plant layouts and components with staggered service intervals result in unplanned stops, reducing overall plant availability below 92%.
Product Quality Inflexibility: Inability to quickly adjust crusher settings and screen configurations to switch between railway ballast, padbasis, and concrete aggregates without halting production.

How do you consolidate a reliable 300 TPH output from varied feed material while controlling operational costs and maximizing plant uptime? The solution lies in a holistically engineered stationary crushing and screening plant designed specifically for this duty cycle.

2. PRODUK OORSIG

Die OEM 250300tph Stone Crushing Plant is 'n volledige, stationary crushing circuit engineered for highvolume production of certified aggregates from hard rock formations like granite, basalt, en rivierklip. It is designed as a primarytotertiary processing system for contractors and mining operations requiring consistent, highyield output.

Operasionele werkvloei:
1. Primêre vermindering: Dumpfed material is crushed by a robust primary jaw crusher, reducing large feed (≤750 mm) to a manageable size for secondary processing.
2. Sekondêr & Tersiêre verplettering: Material is conveyed to a cone crusher(s) vir verdere groottevermindering, producing intermediate aggregates. A tertiary impact crusher may be integrated for shaping applications.
3. Grootte Klassifikasie: Crushed material is routed through multideck vibrating screens to precisely separate product sizes (bv., 05mm, 510mm, 1020mm, 2031.5mm).
4. Hersirkulasie & Voorraad opgaar: Oversize material is automatically returned via closedcircuit conveyors for recrushing. Onspec product is conveyed to designated stockpiles.

Toepassingsomvang & Beperkings:
Omvang: Ideal for large infrastructure projects (hoofweë, spoorweë), commercial concrete batching plants supply, and permanent quarry sites.
Beperkings: This is a stationary plant requiring foundational work and grid power connection. It is not suitable for frequent relocation. Optimal feed material should have an abrasion index (Ai) below .20 for expected wear part life.

3. KERNKENMERKE

Intelligente beheerstelsel | Tegniese basis: Centralized PLC with loadsharing algorithms | Bedryfsvoordeel: Monitors motor amperage and crusher pressure in realtime to optimize feed rates automatically | ROI impak: Prevents chokefeeding and cavity loss; field data shows up to an 8% increase in throughput efficiency.

Modulêre komponentontwerp | Tegniese basis: Standardized bolttogether modules with preengineered interfaces | Bedryfsvoordeel: Reduces civil works cost and accelerates onsite installation by approximately 30% | ROI impak: Lower capital outlay for site preparation; faster commissioning generates revenue sooner.

HeavyDuty Vibrating Feeder with Grizzly Section | Tegniese basis: Highinertia feeder with adjustable grizzly bars | Bedryfsvoordeel: Removes natural fines prior to primary crushing and ensures steady, regulated feed | ROI impak: Reduces unnecessary work on the primary crusher; industry testing demonstrates a 1520% extension in jaw plate life.

Gesentraliseerde smering & Smeerstelsel | Tegniese basis: Automated singlepoint lubrication lines to all major bearing points | Bedryfsvoordeel: Ensures consistent lubrication intervals during operation; eliminates manual greasing errors | ROI impak: Reduces bearing failure risk; documented increase in mean time between failures (MTBF) by over 25%.

HighEfficiency Cone Crusher Configuration | Tegniese basis: Hydraulic adjustment and clearing systems with advanced chamber profiles | Bedryfsvoordeel: Allows quick CSS changes for product sizing without tools; automatic tramp release protects the machine | ROI impak: Minimizes adjustment downtime; improves yield of premium chip products by up to 12%.

Dust Suppression Integration Points | Tegniese basis: Preinstalled piping manifolds at transfer points with nozzle connections | Bedryfsvoordeel: Enables easy integration of water spray systems to control airborne particulate at source locations | ROI impak: Facilitates compliance with environmental regulations; reduces cleanup costs and operator exposure.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (250300tph Plant) | OEM 250300tph Solution | Voordeel (% verbetering) |
|||||
| Overall Plant Availability | ~91% | ≥94% | +3.3% |
| Power Consumption per Ton | ~0.85 kWh/t | ≤0.78 kWh/t |8.2% |
| Wear Part Cost per Ton (Primêr) | $0.12 $0.18/t | $0.09 $0.14/t |25% (at midpoint) |
| Opstelling & Ingebruikneming Tyd | 1216 weke | 811 weke |31% |
| Product Yield within Specification ±5% ±2% +60% consistency |

5.TEGNIESE SPESIFIKASIES

Ontwerp kapasiteit: Guaranteed output of 250 ton per uur; capable of peak outputs up to 320 tph depending on feed material and product size configuration.
Kragvereistes: Totale geïnstalleerde krag ongeveer 450500 kW. Requires stable grid connection or equivalent generator setup.
Materiaalspesifikasies: Handles compressive strength ≤350 MPa. Main frame constructed from Q345B steel; wear liners use Mn18Cr2 or equivalent highchromium iron.
Fisiese afmetings (Tipiese uitleg): Entire plant footprint ~70m (L) x 45m (W). Maximum height ~15m at conveyor discharge points.
Omgewingsbedryfsreeks: Designed for ambient temperatures from 20°C to +45°C with proper lubricants/fluids.

6\. TOEPASSINGSSCENARIO'S

Highway Base Course Production

Challenge A national contractor needed a guaranteed minimum of 280 TPH of Class II road base material (31.5mm) from abrasive basalt rock but faced constant liner wear issues causing unpredictable downtime.
Solution Implementation of the OEM plant featuring the heavyduty feeder/grizzly section paired with highefficiency cone crushers configured specifically for abrasive rock.
Results Wear part intervals increased by over two operating shifts between changes while maintaining consistent throughput of >290 TPH over an eightmonth project duration.

Commercial Aggregate Quarry Expansion

Challenge A quarry supplying multiple concrete plants required increased flexibility to produce four distinct aggregate products simultaneously without sacrificing total volume or resorting to manual sorting.
Solution The modular design allowed integration of an additional screen deck into the circuit alongside precise conveyor routing controls managed by the central PLC system.
Results The plant achieved simultaneous production of sand (04mm), skyfies (410mm), medium aggregate (1020mm),and drainage stone(2031\.5mm).Product changeover time was reduced from hours down to minutes via automated settings

7\. KOMMERSIËLE OORWEGINGS

Pricing tiers are structured around core equipment configuration:
• Tier I – Base Configuration Includes primary jaw secondary cone tertiary impactor basic screening module conveyors central control panel Starting price range
• Tier II – Enhanced Configuration Adds automated metal detection dust suppression system extended walkways service platforms Premium price range
• Tier III – Custom Configuration Incorporates specialized wear liners dual power source capability advanced particle shape analysis integration Custom pricing

Optional Features Include remote monitoring telematics package sound attenuation enclosures automatic sampler systems

Service Packages Available:
• Basic Warranty – Standard parts warranty covering manufacturing defects
• Comprehensive Service Plan – Includes scheduled maintenance inspections wear part kits priority technical support
• Full Operations Contract – Covers total operational maintenance including labor parts performance guarantees

Financing Options Flexible project financing leasing arrangements or leasetopurchase plans can be structured typically over threetosevenyear terms subject to credit approval

8\. Gereelde vrae

Q What are the primary electrical requirements?
A The complete plant requires a threephase supply at approximately kV depending on local infrastructure Total connected load will be provided in detailed specifications

Q Can this plant be integrated into an existing site layout?
A Yes The modular design allows adaptation within reason Our engineering team can review your site plan flow diagram

V Hoeveel operateurs word benodig?
A Typically two personnel are sufficient one at the control cabin monitoring feeds one performing general inspection duties due automation level

Q What lead time can we expect after order placement?
A Lead times vary based configuration current order book Standard Tier I plants generally have delivery within months exworks

Q Are spare parts readily available globally?
A We maintain regional distribution centers critical wearing parts ensuring availability within hours major markets days elsewhere

Q Does price include installation supervision commissioning?
A Pricing exworks Supervision commissioning offered as separate service package recommended ensure optimal startup performance