1. فتحة مدفوعة بنقطة الألم

تعمل تكاليف التشغيل المتصاعدة وفترات التوقف غير المتوقعة على تآكل هوامش الرمال والحصى لديك? Managing a modern aggregate operation presents distinct challenges that standard equipment often fails to address. Consider these common, costly scenarios:
ملابس عالية & تكاليف الصيانة: Abrasive silica and gravel rapidly degrade standard components, مما يؤدي إلى كثرة, unscheduled shutdowns for liner changes, pump rebuilds, and conveyor belt replacements.
عدم تناسق جودة المنتج النهائي: Fluctuations in feed material cause offspec product—fines content too high or particle distribution out of grade—resulting in rejected loads and lost revenue.
Inefficient Water & Sludge Management: Ineffective washing and clarification systems waste process water, create environmental compliance hurdles, and lose valuable fines to settling ponds.
انخفاض كفاءة المصنع بشكل عام: Bottlenecks at crushing, الفحص, or material handling stages limit total throughput, preventing you from capitalizing on highdemand periods.

What if your key processing equipment was engineered from the ground up to confront these specific abrasion, تصنيف, and reliability challenges? The solution lies in partnering with a specialized contract manufacturer for your core sand gravel mining equipment.

2. نظرة عامة على المنتج

This content details a comprehensive line of stationary and modular sand washing, تصنيف, and dewatering equipment manufactured under contract for sand and gravel mining operations. As your contract manufacturer, we engineer and build the core machinery that transforms raw feed into specification aggregate.

سير العمل التشغيلي:
1. يٌطعم & توزيع: Crushed material is evenly distributed into the washing system.
2. الاستنزاف & تحرير: Rotating paddles or screws scrub particles to break down clay clots and liberate fines from coarse aggregate.
3. التصنيف الهيدروليكي: Precise water flow rates separate particles by size and specific gravity in settling tanks or hydrocyclones.
4. Mechanical Dewatering: Screws or vibratory decks remove excess water from fine and coarse products to meet shipping moisture specifications.
5. استرداد الغرامات & إدارة المياه: Integrated cyclones and thickeners capture ultrafine particles for byproduct sale while clarifying water for recirculation.

نطاق التطبيق: مثالية لمعالجة الركام البكر, crushed stone rewashing, and construction/demolition material recycling. Primary limitations include maximum feed size (typically ≤1”) and the requirement for a consistent water supply; dry processing solutions are configured separately.

3. الميزات الأساسية

Polyurethane Wear Components | الأساس الفني: Advanced elastomer casting with high tear strength | المنفعة التشغيلية: Outlasts standard rubber liners by 300500% in abrasive silica applications | تأثير عائد الاستثمار: Reduces component changeout frequency by over 60%, lowering parts inventory costs and maintenance labor hours.

محرك التردد المتغير (VFD) يتحكم | الأساس الفني: Precision AC motor speed regulation via programmable logic controller (بلك) | المنفعة التشغيلية: Operators can instantly adjust screw speed or slurry density in response to feed changes | تأثير عائد الاستثمار: Maintains onspec product yield, reducing waste by an average of 15% as per field data.

Unified Rinse Water System | الأساس الفني: Pressurized manifold distributing clarified water across final rinse screens | المنفعة التشغيلية: Ensures thorough cleansing of final product without increasing fresh water consumption | تأثير عائد الاستثمار: Lowers fresh water makeup requirements by up to 30%, reducing pumping costs and environmental footprint.

BoltTogether Modular Chassis | الأساس الفني: Fabricated structural steel design with predrilled connection points | المنفعة التشغيلية: Enables rapid site relocation or plant reconfiguration with minimal cutting/welding | تأثير عائد الاستثمار: Cuts redeployment time by 50%, allowing faster response to shifting deposit locations.

Integrated Cyclone Cluster Packages | الأساس الفني: Bank of smalldiameter hydrocyclones for highG force separation | المنفعة التشغيلية: Recovers ultrafine sand (100400 شبكة) from waste streams for sale as a byproduct | تأثير عائد الاستثمار: Adds a new revenue stream; typical plants report payback on this module in under 12 شهور.

نظام تشحيم الشحوم المركزي | الأساس الفني: Automated manifold delivering grease to all critical bearings on timed intervals | المنفعة التشغيلية: Eliminates manual greasing points in hardtoreach locations, ضمان الحياة تحمل الأمثل | تأثير عائد الاستثمار: Documented reduction in bearingrelated failures by over 80%, protecting against catastrophic downtime.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة القياسي | Our Sand Gravel Mining Contract Solution | ميزة موثقة |
| : | : | : | : |
| Liner Life in Abrasive Silica Sand | 750 1,000 ساعات العمل | 3,000 4,000 ساعات العمل (مادة البولي يوريثين) | +300% تحسين |
| Fresh Water Consumption per Ton Processed| ~100 gallons/ton (حلقة مفتوحة) | ~70 gallons/ton (نظام حلقة مغلقة) | 30% تخفيض |
| استعادة المواد الدقيقة (92% recovery to product stream (with cyclone pack) | +27 نقاط مئوية |
| متوسط ​​الوقت بين الفشل (MTBF) محركات الأقراص الحرجة| ~ 2000 ساعة| >4,500 ساعات (with VFD & التشحيم المركزي)| +125% تحسين |
| OnSpec Product Consistency (تدرج)| ±5% variation from target sieve| ±2% variation from target sieve (with VFD control)| تم تقليل التباين بنسبة 60% |

5. المواصفات الفنية

سعة نطاق النموذج: من 50 TPH pilot/test units to highvolume 450 TPH production plants.
متطلبات الطاقة: Plantdependent; typical single module ranges from 75 HP ل 250 HP total connected load at 480V/3Phase/60Hz (other voltages configurable).
مواصفات المواد: Primary wear components constructed from ASTMrated abrasionresistant steel (>400 بي إتش إن), cast polyurethane (>95A Durometer), and ceramic linings in ultrahigh wear zones.
الأبعاد المادية (Typical Single Screw Washer): طول: ~35’, عرض: ~10’, ارتفاع: ~15’. Modular design allows for stacking or sidebyside placement.
نطاق التشغيل البيئي: مصممة لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +50 درجة مئوية (4°F to 122°F). Dust enclosures and heated bearing options available for extreme environments.

6. سيناريوهات التطبيق

منتج الرمل التجاري – الغرب الأوسط للولايات المتحدة الأمريكية

تحدي: A producer faced significant profit loss due to high silt/clay content contaminating final concrete sand products, leading to frequent customer rejections.
حل: Implementation of a highcapacity fine material washer with an integrated attrition cell and cyclonebased fines recovery system.
نتائج: Reduced deleterious materials content from >6% ل <0.5%. The recovered fines were sold as a filler material. Overall plant profitability increased by an estimated $12/ton on washed concrete sand.

Alluvial Gravel Pit Operator – Western Canada

تحدي: Seasonal freezing conditions caused severe downtime during spring thaw due to sedimentladen process water that could not be effectively clarified for recirculation.
حل: Contract manufacturing of a modular washing plant featuring a highcapacity deep cone thickener for rapid solids settling and sludge densification.
نتائج: Achieved closedloop water recycling within 48 hours of seasonal startup versus the previous twoweek average. Reduced fresh water procurement costs by over $45,000 annually and ensured consistent earlyseason production.

7. الاعتبارات التجارية

Our contract manufacturing model provides flexibility tailored to your operational scale:
طبقات التسعير: على أساس القدرة (الهيدروكربونات النفطية في الساعة) and complexity—from standard singlescrew washer packages (300 الهيدروكربونات النفطية في الساعة).
الميزات الاختيارية / ترقيات: Common upgrades include automated polymer dosing systems for fines flocculation , حزم التحكم عن بعد للمراقبة عن بعد , مجموعات بداية قطع الغيار ,and custom discharge chute configurations .
حزم الخدمة: Choose from annual preventative maintenance inspections , guaranteed parts availability programs with defined SLAs ,and ondemand technical support .
خيارات التمويل: We work with thirdparty financial institutions who specialize in heavy equipment financing . Solutions include capital leases , عقود الإيجار التشغيلية ,and leasetoown structures designed around project cash flow .

8. التعليمات

س1: Is your equipment compatible with our existing crushing plant setup?
نعم . Our systems are designed as both standalone plants or as bolton modules . We require your existing plant’s discharge conveyor height , معدل التغذية ,and available power specifications . Our engineering team will provide detailed interface drawings .

Q2:ما هو التأثير المتوقع على إنتاجية المصنع الإجمالية؟?
By eliminating bottlenecks at the washing stage , most operations see an increase in total usable output . Field data shows plants often realize a net gain of between1020 %in salable tons per hour due reduced waste material handling .

س3:What are typical lead timesfor contractmanufactured equipment?
Lead times varyby complexity . For standard designs we maintain partial inventoryof key components ;typical delivery is1418 weeksfrom order approval . Custom engineered solutions require2226 weeksfor full fabrication assembly testing .

س 4:What commercial terms do you offer?
Standard commercial terms involvea progress payment schedule tiedto major manufacturing milestones :30 %upon order40 %upon major fabrication completion25 %upon completionof factory acceptance testing5 %upon shipment .

س5:What levelof operator trainingis provided?
We include comprehensive onsite trainingfor both operationsand maintenance crewsas partof commissioning This covers normal startup/shutdown procedures routine maintenance troubleshooting guidesand safety protocols Documentation includesfull electrical schematics parts manuals lubrication schedules

س6:Canyour systems handle recycled concreteor asphalt millings(موسيقى الراب)?
Yes but this requires specific configuration Heavily soiledor contaminated C&D debris often needs enhanced attrition scrubbing We recommend providinga sampleof your feedstockfor pilot testingto determine the optimal machine parameters

س7:Doyou provide performance guarantees?
We provide mechanical performance guaranteescovering workmanship materials Additionally we can establish process performance criteria basedon pilot test resultsor agreedupon feed specifications These are detailed within the commercial proposal