1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare beskikbaarheid erodeer jou ysterertsverwerkingsmarges? Vir aanlegbestuurders en ingenieurskontrakteurs, the primary crushing stage is a critical bottleneck with direct consequences for your entire operation. Algemene uitdagings sluit in:

Oormatige stilstand vir instandhouding: Gereelde voeringveranderings en onbeplande herstelwerk aan jou primêre breker stop die hele voerstelsel, duisende per uur in verlore produksie kos.
Hoë slytasie-onderdeelkoste & Verbruik: Abrasive iron ore rapidly degrades crusher components, leading to unsustainable spending on manganese steel and arduous, laborintensive replacement cycles.
Inkonsekwente vermindering van voergrootte: Fluctuations in feed size or hardness can cause choke feeding or cavity flooding, reducing throughput and creating downstream processing instability.
Rigid Plant Layout Constraints: Fixed primary crushing stations lack mobility, complicating mine plan progression and requiring costly overburden removal or lengthy rehandling.

Is your current solution equipped to handle increasingly hard and abrasive ore bodies while maintaining costpertonne targets? A strategically selected private label iron ore crushing plant provides a tailored answer to these systemic challenges.

2. PRODUK OORSIG

A private label iron ore crushing plant is a heavyduty, semistationary or modular primary crushing system engineered specifically for the highvolume, highabrasion reduction of runofmine (ROM) ystererts. These plants are manufactured under contract to meet precise operational specifications and are branded for the distributor or large contractor.

Operasionele werkvloei:
1. ROM-ontvangs & Voorafskerm: Direct dump from haul trucks onto a robust grizzly or scalping screen to bypass subfines material.
2. Primêre groottevermindering: Oversize material is conveyed to a highcapacity jaw crusher or gyratory crusher for initial reduction to a manageable transport size (tipies <250mm).
3. Primary Stockpiling: Crushed product is conveyed to a live stockpile, providing crucial surge capacity for downstream processing circuits.

Toepassingsomvang: Ideal for greenfield site development, dedicated processing lines for specific ore types, or as a supplemental primary station for existing operations. Best suited for operations with a defined mine life and consistent feed characteristics.

Beperkings: Not designed as portable trackmounted units for frequent relocation. Maximum efficiency is achieved with proper feed control and consistent ore geology. Requires foundational civil works and integration engineering.

3. KERNKENMERKE

HeavyDuty Crusher Frame | Tegniese basis: Eindige Element Analise (FEA) geoptimaliseerde stresverspreiding | Bedryfsvoordeel: Elimineer krake van raammoegheid onder skokladings van onbreekbare materiaal | ROI impak: Verminder die risiko van katastrofiese strukturele mislukking, extending asset service life beyond 10+ jare

Skuurweerstandige materiaalvloeistelsel | Tegniese basis: Hardox® or equivalent wear steel in hoppers, rompe, and chutes; ceramic lagging on critical pulley faces | Bedryfsvoordeel: Dramatically reduces material adherence and wearthrough in transfer points | ROI impak: Cuts maintenance welding/replacement frequency by up to 60%, lowering direct labor and parts costs

PLCBased Automated Control & Monitering | Tegniese basis: Centralized programmable logic controller with loadsharing algorithms and remote telemetry capability | Bedryfsvoordeel: Optimizes crusher power draw, prevents choke events, en verskaf intydse operasionele data | ROI impak: Verbeter deurvloeikonsekwentheid met 'n geskatte 812% while enabling predictive maintenance scheduling

Modulêre vervoerband & Looppad Ontwerp | Tegniese basis: Bolttogether sections with standardized dimensions | Bedryfsvoordeel: Enables faster installation onsite and allows future reconfiguration as mine layout evolves | ROI impak: Reduces initial construction time/cost by approximately 1520% versus fully welded structures

Gesentraliseerde Lube & Hidrouliese stelsel | Tegniese basis: Singlepoint lubrication lines to all major bearings; dedicated hydraulic power unit for crusher adjustment/clearing | Bedryfsvoordeel: Simplifies routine servicing intervals and enhances operator safety during maintenance tasks | ROI impak: Decreases scheduled maintenance downtime windows by an average of 30%

Geïntegreerde stofonderdrukkingsspruitstuk | Tegniese basis: Nozzle system plumbed into primary transfer points, tied to conveyor operation sensors | Bedryfsvoordeel: Actively controls dust at source, die sigbaarheid van die terrein en die nakoming van omgewingsregulasies te verbeter | ROI impak: Versag risiko van regulatoriese boetes en verminder opruimkoste

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Generiese plant) | Private Label Iron Ore Crushing Plant Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Liner Life (Mn Staal)| 450,000 550,000 ton| 600,000 750,000 ton| +25% aan +35% |
| Gemiddelde tyd tussen mislukking (MTBF)| ~720 hours| ~1,100 hours| +53% |
| Tonnage Throughput Consistency| ±15% variance from target| ±7% variance from target| >50% improvement in stability |
| Tydsduur van installasie op die terrein| 1216 weke| 810 weke| ~33% reduction |
| Spesifieke kragverbruik| Maatstaf = 100%| Bereik 9295% of benchmark| 58% verbetering in energiedoeltreffendheid |

5. TEGNIESE SPESIFIKASIES

Kapasiteitgradering: Konfigureerbaar vanaf 1,200 oor 3,500 ton per uur (TPH), based on crusher selection.
Primêre Crusher Opsies: Enkel-wisselkaakbreker (1.2m x 1.5m up to 1.6m x 2.0m) of Primêre Gyratoriese Breker (4265 reeks).
Kragvereistes: Total installed power typically between 450kW 900kW depending on configuration; supplied at either 6.6kV or medium voltage.
Materiaalspesifikasies: Primêre struktuur ASTM A36 koolstofstaal; wear surfaces Hardox® 450/500; crusher liners ASTM A128 Manganese Steel.
Fisiese afmetings (Tipies): Footprint approximately 25m L x 18m W x 15m H (excluding feed ramp and discharge stockpile).
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +45°C; dust protection rating of IP65 for electrical enclosures.

6. TOEPASSINGSSCENARIO'S

Direct Feed Hematite Operation

Uitdaging: An existing hematite operation used a legacy crusher located far from the new pit face, requiring doublehandling by loaders and incurring high hourly equipment rental costs.
Oplossing: Implementation of a private label iron ore crushing plant with a deeppit receiving hopper adjacent to the new pit rim.
Resultate: Elimination of loader rehandling reduced operating costs by approximately $0.85 per tonne hauled. The plant achieved design throughput within two weeks of commissioning.

Magnetite Concentrator Expansion

Uitdaging: A magnetite concentrator needed to increase primary crushed tonnage by over onethird but had limited space within the existing fixed infrastructure footprint.
Oplossing: Deployment of a modular private label crushing plant designed with vertical stacking conveyors to fit the constrained site layout.
Resultate:The modular design reduced civil works by an estimated $300k USD compared to traditional construction.The expansion was completed during a planned twoweek shutdown with no further production delays.

HighAbrasion Banded Iron Formation

Uitdaging:A new BIF deposit exhibited higherthanaverage abrasiveness index values,causing premature failure of conveyor belts,breker voerings,and chutes in test runs using standard equipment.
Oplossing:A bespoke private label solution featuring enhanced wear packages,a slowerspeed jaw crusher configuration,and specialized impact beds on all transfer points.
Resultate:Liner life improved by over onethird against initial projections.Conveyor belt replacement intervals extended from six months back toward standard ninemonth cycles,saving $120k annually in belt costs alone.

7.KOMMERSIËLE OORWEGINGS

Equipment pricing tiers are structured around core crusher selection:

Vlak I(HighCapacity Jaw Crusher Based):For midrange tonnage requirements.Capital cost range:$2M$4M USD depending on options.
Vlak II(Primary Gyratory Crusher Based):Vir maksimum deurset (>2，500 TPH)and hard，abrasive ores.Capital cost range:$4M$7M USD depending on options.

Opsionele kenmerke:
OnBoard Power Generation Package
Gevorderde deeltjiegrootte-monitering(PSM)Stelsel
Outomatiese smeerstelsels
Full Perimeter Dust Containment Skirting

Dienspakkette:
Ingebruikneming & Operateursopleiding(Standaard)
Jaarlikse inspeksie & Parts Kitting Agreement
FullService Maintenance Contract with guaranteed uptime SLA

Finansieringsopsies:
Available through partner financial institutions including operating lease structures，capital leasetoown plans，or projectbased financing tailored for mining developments.This allows preservation of capital while securing critical production infrastructure.

8.Gereelde vrae

V:What level of customization is possible with a private label plant versus an OEM standard model?
A：Significant customization is core to the value proposition.You can specify crusher manufacturer，drive motor suppliers，conveyor belt grade，control system brand（e.g.,Siemens，AllenBradley），and structural details like access stair placement.This ensures compatibility with your existing spares inventory和maintenance practices。

V：How does this solution integrate with my existing secondary crushing circuit和downstream processing？
A：The plants are engineered based on your required final product size（typically 250mm）for optimal secondary circuit feed.Design parameters include discharge height，conveyor speed和transfer point geometryto match your existing receiving hoppers或stockpile conveyors seamlessly。

V：What are the lead times from order placementto commissioning？
A：Lead times vary but typically range from32to48weeksfor complete plants.This includes detailed engineering，vervaardiging，shop assembly testing，dismantlementfor shipment和reassemblyon your site。Versnelde opsies kan beskikbaar wees。

V：Kan u prestasiewaarborge verskaf?
A：Ja。Performance guaranteesfor throughput capacity based on agreed feed material specificationsand product sizeare standardin contracts。Wear rate guaranteesfor key components like linerscan also be structuredbased on agreed abrasiveness indices。

V：Who holds responsibilityfor equipment warranties？
A：The private label dealer holds ultimate responsibilityfor warranty administration。Components are coveredby their original manufacturer's warranties（e.g.,crusher,laers,motors），while structuraland assembly workmanshipis warranted directlyby the fabricator under our singlepoint accountability。

V：What trainingand documentationare provided？
A：Comprehensive documentation包括asbuilt drawings,P&ID's，electrical schematics，parts manuals和lubrication schedules。Onsite trainingfor operationsand maintenance crews is conductedduring commissioningwith both classroomand handson modules。

V：Are these plants suitablefor remote locationswith limited service support？
A：Ja。They are designedwith serviceabilityas apriority。Common component standardization,easy access platformsand designedin service tool clearances reduce required skill levelsfor routine tasks。Remote monitoring capabilityallows our support teamsto assistwith diagnosticsoffsite。