1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant is a critical asset, yet common operational challenges directly impact your bottom line. Consider these frequent issues:
Inconsistent Throughput & Downtime: Unplanned stoppages due to feeder blockages, crusher overloads, or conveyor misalignment can cost thousands per hour in lost production and idle labor.
High Operational & Maintenance Costs: Frequent wear part replacement, high energy consumption per ton of output, and the need for specialized maintenance crews steadily increase your cost per aggregate ton.
Poor Product Shape & Gradation Control: Inconsistent output leads to excess fines or outofspec material, reducing the market value of your end product and causing rejections.
Rigid Plant Layout & Scalability Limits: Fixed designs struggle to adapt to changing feed material hardness or required product mixes, forcing costly retrofits or operating below optimal capacity.

How do you achieve stable, highyield production while controlling costs and ensuring final product quality? The solution lies in a robustly engineered 250300tph stationary crushing plant designed for predictable performance.

2. PRODUCT OVERVIEW

This solution is a complete stationary stone crushing and screening plant engineered for a nominal output of 250 to 300 metric tons per hour (tph) of finished aggregate. It is designed as a primarytotertiary processing system for mediumhard to hard stones like granite, basalt, and limestone.

Operational Workflow:
1. Primary Crushing: Large feed material (≤750mm) is reduced by a heavyduty jaw crusher or gyratory crusher.
2. Secondary & Tertiary Crushing: The primary crushed material is further processed by cone crushers for size reduction and improved particle shape.
3. Screening & Classification: Vibrating screens separate material into precise size fractions, routing oversize back to crushers and directing onspec product to final stockpiles.

Application Scope: Ideal for large quarry operations, major infrastructure project support (highways, railways), and commercial aggregate supply yards requiring highvolume, consistent output.

Key Limitations: Feed material hardness must be within specified limits (e.g., up to 300 MPa compressive strength). Plant requires stable foundation preparation and gridbased power connection. Not designed for mobile or frequent relocation.

3. CORE FEATURES

Intelligent Feed Control System | Technical Basis: Variable Frequency Drive (VFD) on primary feeder with level sensors | Operational Benefit: Prevents crusher cavity overload and minimizes bridging, ensuring smooth material flow | ROI Impact: Reduces unplanned downtime by up to 15% and improves crusher liner life

Laminated Crushing Chamber Design | Technical Basis: Multilayer crushing cavity geometry in cone crushers | Operational Benefit: Produces superior particle shape with lower flakiness index and controlled fines generation | ROI Impact: Increases premium product yield by 812%, enhancing sales revenue

Centralized Greasing & Hydraulic System | Technical Basis: Singlepoint lubrication stations with automated timers and pressure monitoring | Operational Benefit: Ensures critical bearing points are serviced consistently, reducing failure risk | ROI Impact: Lowers bearingrelated breakdowns by an estimated 25% and extends service intervals

HighStrength Modular Conveyor Framework | Technical Basis: CADoptimized truss design using hightensile steel | Operational Benefit: Provides exceptional stability under load, reducing vibration and misalignment issues | ROI Impact: Decreases conveyor maintenance time by approximately 20% over the plant lifecycle

PLCBased Automated Process Logic | Technical Basis: Programmable Logic Controller with humanmachine interface (HMI) for sequence control and interlocking | Operational Benefit: Allows singleoperator oversight of startup/shutdown sequences and provides fault diagnostics | ROI Impact: Optimizes power use during operation cycles and reduces labor requirements for plant control

HeavyDuty Vibrating Screen with QuickChange Decks | Technical Basis: Rubber shear mounts and sidetensioned screen media attachment system | Operational Benefit: Provides efficient sizing with reduced noise/vibration transmission; enables faster screen cloth replacement | ROI Impact: Cuts screen maintenance downtime by up to 40% per changeout event

Integrated Dust Suppression System | Technical Basis: Nozzle arrays at transfer points connected to a highpressure pump system | Operational Benefit: Effectively controls airborne particulate at primary dust generation sources | ROI Impact: Ensures compliance with environmental regulations, avoiding potential fines and improving site working conditions

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This 250300tph Stone Crushing Plant Solution | Advantage (% improvement) |
|||||
| Overall Equipment Effectiveness (OEE) | ~76% | Target ≥84% | +10.5% |
| Power Consumption (kWh/ton processed) | Varies widely; baseline = X | Optimized system design reduces baseline |7% to 12% |
| Crusher Wear Part Life (Manganese Liners)| Based on abrasive feed | Improved chamber design & alloy selection |15% Cost Per Ton |
| Mean Time Between Failures (MTBF) Key Conveyors ~1,200 hours ~1,650 hours +37.5% |
| Product Shape Index (Flakiness) Typically >20% Maintains <15% 25% Improvement in Cubicity |

5. TECHNICAL SPECIFICATIONS

Nominal Capacity Range: 250 – 300 tph (varies based on feed material hardness & required product gradation).
Primary Crusher Options: Jaw Crusher (PE900×1200) or Gyratory Crusher; Feed Opening up to 750mm.
Secondary/Tertiary Crushers: Multicylinder Hydraulic Cone Crushers.
Screening Equipment: Tripledeck heavyduty circular motion vibrating screens; Total screening area ≥20m².
Total Installed Power: Approximately 550 – 650 kW (dependent on configuration).
Key Material Specifications: Primary frame construction Q345B steel; Highwear components use Mn18Cr2 or equivalent alloys; Conveyor belts rated for minimum PIW 800.
Overall Plant Footprint (LxW): Approximately 85m x 65m (layout dependent). Height restrictions apply (~25m max).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; Dust emission control achieves ≤20mg/m³ at key points.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A quarry needed to increase production from 200tph to a consistent 280tph of road base and concrete aggregates but had limited space for plant expansion.
Solution Implementation of a compact vertical layout using this configured plant with multicylinder cone crushers for secondary/tertiary stages.
Results Achieved steadystate output of 290tph within the existing footprint. Product cubicity met the highest local specification standards.

LargeScale Highway Construction Support

Challenge A contractor required an onsite crushing setup capable of processing blasted limestone at high volume while maintaining strict gradation bands for multiple subbase layers.
Solution Deployment of this complete stationary crushing plant including advanced screening modules with precise deck configurations.
Results The plant supplied over 1.2 million tons of spec material across three years with less than five percent deviation from required gradation curves.

7. COMMERCIAL CONSIDERATIONS

Our solutions are offered in tiered configurations:
Standard Configuration Tier: Includes core crushing modules,screening units,and basic PLC control.Priced as a turnkey package.
HighEfficiency Tier: Adds intelligent feed systems,crusher automation settings,and premium wear materials.Initial investment yields lower longterm operating costs.
Custom Engineering Tier: For nonstandard applications requiring specific layouts or special material handling components.Priced upon project engineering review.

Optional features include advanced dust collection baghouses,tiremounted mobile primary units for flexible feeding,and remote monitoring telematics packages.Service agreements range from basic scheduled maintenance plans to comprehensive annual partsandlabor coverage.Financing options including equipment leasing are available through our partners.

8. FAQ

What are the primary power requirements?
A stable threephase industrial power supply is required.Total connected load typically ranges from550to650kW.Detailed electrical schematics are providedfor grid connection planning.

Can this plant process river gravel or very abrasive materials?
While designedfor hard rock,the wear package can be specifiedwith enhanced alloysfor highly abrasive feeds.Consult our engineering teamfor specificmaterial test analysisand configuration recommendations.

What is the typical installationand commissioning timeline?
From foundation handoverto full production,the process typically requires8to12weeks.This includes mechanical erection,electrical connection,system calibration,and operator training conductedby our engineers.

Do you provide spare parts support globally?
We maintaina centralized spare parts depotand workwith regional logistics partners.We guarantee availabilityof critical wear partsand offera guaranteed48hour dispatchfor stocked items under service agreements.

How does thisplant handle variationsin feed sizeor hardness?
The PLCcontrolled system allows adjustmentsof crusher settings(via the HMI)and feeder rates.The hydraulic adjustmenton cone crushers enables quickcompensationfor changesin material characteristicsto maintainoutput quality