1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, commercial crushing and screening operations face persistent challenges: high perton processing costs from inefficient equipment, excessive maintenance hours consuming labor budgets, and unplanned stoppages that cascade through your production schedule. You contend with inconsistent final product specs leading to rejected loads, rapid wear part consumption in abrasive environments, and the logistical complexity of managing multiple machines across a site.

What if your primary and secondary reduction stages could be more predictable? How would a 15% reduction in fuel consumption per ton impact your quarterly operating statement? Is there equipment designed not just for peak output, but for sustained, costeffective performance in demanding commercial cycles? The solution lies in specifying machinery engineered for total cost of ownership, not just initial purchase price.

2. PRODUCT OVERVIEW

This product line encompasses a range of mobile and stationary commercial crushing and screening equipment designed for highvolume aggregate production, C&D recycling, and mineral processing applications. The operational workflow is engineered for linear efficiency: (1) Primary jaw or impact crushing reduces feed material to a manageable size. (2) A conveyor system transfers sized material to a secondary cone or impact crusher for further reduction. (3) The screened unit then separates the crushed material into precise specification grades using multideck vibrating screens. (4) Oversize material is recirculated back to the secondary crusher in a closedcircuit configuration. (5) Final spec products are stockpiled via radial or stacking conveyors.

This equipment is suited for processing natural rock, recycled concrete, asphalt, and industrial minerals. It is not designed for ultrahard abrasive feeds (e.g., granite) without specific liner configurations, nor for wet, sticky materials without prescreening and washing options.

3. CORE FEATURES

Direct Drive Crusher System | Technical Basis: Eliminates Vbelts and reducers; couples crusher directly to hydraulic motor or diesel engine via clutch | Operational Benefit: Reduces power transmission losses by up to 8%, lowers maintenance points, enables instant reversal to clear blockages | ROI Impact: Measurable fuel savings per ton crushed; reduced risk of downtime from belt failure.

Tier 4 Final / Stage V DieselElectric Hybrid Option | Technical Basis: Diesel engine runs at constant optimal RPM to generate electricity for individual electric motors on crusher, screens, and conveyors | Operational Benefit: Up to 20% lower fuel consumption versus direct diesel drives; significantly quieter operation for urban sites; precise power management | ROI Impact: Direct reduction in operating cost; enables work in noisesensitive areas with longer permitted hours.

Unified PLC Control & Telematics System | Technical Basis: Centralized programmable logic controller with CANbus architecture provides realtime monitoring of all machine functions | Operational Benefit: Operators can adjust crusher speed, feeder rate, and screen angle from a single console; remote diagnostics alert to performance deviations | ROI Impact: Faster setup and calibration between material changes; predictive maintenance alerts prevent catastrophic failures.

HighStrength Rolled Steel Frame & StressRelieved Welds | Technical Basis: Fabricated from uniform tensile strength steel with postweld heat treatment to eliminate internal stresses | Operational Benefit: Frame resists fatigue cracking under cyclical loading, extending structural life beyond standard commercial duty cycles | ROI Impact: Higher residual value; eliminates costly midlife frame repairs or reinforcement.

Modular Wear Part Design | Technical Basis: Interchangeable liner segments and boltin wear plates on hoppers, feeders, and chutes | Operational Benefit: Reduces changeout time by up to 40%; allows strategic rotation of components to maximize wear life | ROI Impact: Lowers labor cost per maintenance event; extends mean time between replacements.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for Commercial Equipment | This Commercial Crushing & Screening Solution | Advantage (% improvement) |
| : | : | : | : |
| Avg. Tons per Gallon Fuel Processed| 80 100 tons/gallon (for midsize tracked plant) | 108 115 tons/gallon (hybrid drive system) | +1520% efficiency |
| Wear Part ChangeOut Time (Primary Jaw Liners)| 68 hours (2person crew) | 3.54.5 hours (modular design & hydraulic assist) | ~45% faster |
| Screen Deck Media Replacement Time| 46 hours per deck (woven wire) | 1.52 hours per deck (boltin polyurethane panels) | ~65% faster |
| Setup/Teardown Time for Relocation| Full Day (810 hrs) with cranes/assists| Half Day (45 hrs) with integrated hydraulic systems| ~50% reduction |

_Field data based on comparative studies in limestone quarry applications._

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 to over 600 tons per hour depending on feed material density and final product specification.
Power Requirements: Options include:
Tier 4 Final Diesel Engine(s): 350 750 HP total.
DieselElectric Hybrid System: Primary genset @ 400 kVA.
Full Electric Plant Option: Requires external 400V/50Hz or 480V/60Hz supply.
Material Specifications: Crusher jaws/cones manufactured from manganese steel (14%18%). Chute liners available in AR400 steel or replaceable polyurethane. Screen boxes constructed from highyield strength steel.
Physical Dimensions (Mobile Tracked Plant Example): Transport length approx. 1822m; Operating height approx. 45m; Working weight between 45 75 metric tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system standard; sounddampened package available achieving <85 dB(A) at 10 meters.

6. APPLICATION SCENARIOS

Urban C&D Recycling & Aggregate Production

Challenge: A contractor needed to process mixed construction debris into certified base materials within city limits under strict noise ordinances and limited daily operating windows.
Solution: Implementation of a closedcircuit hybridpowered commercial crushing and screening equipment setup with sound enclosures.
Results: Achieved consistent production of three spec products simultaneously at <82 dB(A). Fuel costs reduced by an estimated $11,500 over a sixmonth project versus traditional plant. Extended daily permitted hours by two due to compliant noise levels.

Regional Aggregate Quarry Expansion

Challenge: A quarry operator faced rising maintenance costs and downtime on aging spread units used for producing road base aggregates.
Solution: Replaced two separate machines with a single highcapacity mobile impact crusher/screen combination featuring modular wear parts.
Results: Plant availability increased from an average of 82% to over 94%. Maintenance labor hours dedicated to the crushing circuit fell by an estimated third annually while throughput increased by approximately twenty percent due to higher reliability.

7. COMMERCIAL CONSIDERATIONS

Equipment is offered across three primary tiers:
1. Standard Duty: Core configuration ideal for consistent feed materials like limestone/soft rock.
2. Heavy Duty: Includes upgraded wear packages, heavierduty bearings/belts/shafts recommended for mixed/recycled materials or abrasive sand & gravel.
3. HighProduction Premium: Encompasses hybrid drive option advanced telematics with payload reporting automated lubrication systems

Optional features include magnet separators dust suppression cannons additional conveyor lengths sidedischarge conveyors hydraulic screen tensioning

Service packages range from basic warranty extensions through comprehensive scheduled maintenance agreements including guaranteed parts availability within fortyeight hours

Financing options include conventional equipment loans operating leases tailored rentalto own structures structured around seasonal cash flow patterns common in construction

8.FAQ

Q What is required integrate this new equipment into my existing spread?
A Our systems are designed compatibility industrystandard conveyor heights discharge points Most integration involves simple mechanical linkage telematics can often interface existing fleet management software via API

Q How does the hybrid drive system perform cold climates?
A The dieselelectric system uses synthetic fluids maintains battery temperature insulated compartment Field data shows reliable startups down rated temperature limit minus twenty degrees Celsius

Q What typical lead time delivery after order placement?
A For standard configurations lead time typically twelve fourteen weeks Customized builds may require sixteen twenty weeks depending scope modifications

Q Are operator training parts included purchase?
A Yes comprehensive onsite commissioning operator training included all purchases Basic tool kit essential spare parts starter kit also provided minimize initial downtime

Q Can this equipment process reinforced concrete rebar?
A Yes impact crushers specifically configured reinforced concrete feature integrated overband magnet remove rebar hydraulically opening crusher clear potential blockages Standard practice recommend pre picking larger metals

Q What financing structures available independent contractors?
A We offer several programs including seasonal payment plans align project income delayed first payment options We recommend discussing specific business structure cash flow model our commercial team