1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the crushing and screening circuit is often the source of critical bottlenecks. Common challenges include:
Unscheduled Downtime: Component failures in critical crushers or screeners can halt entire lines, costing thousands per hour in lost production and labor.
High Maintenance Costs: Frequent bearing replacements, wear part changes, and alignment adjustments consume both budget and valuable maintenance hours.
Inconsistent Product Gradation: Outdated or poorly configured screening equipment leads to offspec material, resulting in product rejection, reprocessing costs, and dissatisfied customers.
Energy Inefficiency: Older crushing plants can consume excessive power per ton of output, directly impacting your bottom line as energy prices rise.
Scalability Limitations: Fixedconfiguration plants struggle to adapt to changing feed material or market demands for different aggregate sizes.

Is your current equipment addressing these issues, or is it the source of them? The right commercial crushing and screening equipment is not an expense but a strategic investment in predictable, profitable output.

2. PRODUCT OVERVIEW

This product line encompasses heavyduty, stationary and modular crushing and screening plants designed for highvolume aggregate production. Engineered for commercial quarrying, mining, and largescale construction projects, this equipment transforms raw feed (e.g., granite, basalt, limestone) into precisely graded aggregates.

Operational Workflow:
1. Primary Reduction: Raw feed is introduced into a robust primary jaw crusher for initial size reduction.
2. Secondary/Tertiary Crushing: Material is conveyed to cone or impact crushers for further refinement to desired intermediate sizes.
3. Material Screening: Crushed material is distributed across multideck vibrating screens to separate particles by size.
4. Stockpiling & Recirculation: Onspec material is routed to designated stockpiles. Oversize material is automatically recirculated back into the circuit for further processing.

Application Scope: Ideal for hightonnage production of aggregates (3/4" minus, base course, manufactured sand), riprap, and railway ballast.
Limitations: Not designed for very lowvolume (< 150 TPH) operations, portable/tracked applications requiring frequent moves, or processing highly abrasive ores without specific alloy configurations.

3. CORE FEATURES

Hydroset CSS Adjustment | Technical Basis: Hydraulic cylinder support of the crushing mantle | Operational Benefit: Closedside setting (CSS) adjustments can be made in under 60 seconds under load for optimal product size control. | ROI Impact: Minimizes downtime for manual adjustments; increases yield of premium product fractions by up to 15%.

Modular Screenbox Design | Technical Basis: Bolttogether screen frame sections with standardized tensioning rails | Operational Benefit: Individual screen decks or panels can be replaced without dismantling the entire box structure. | ROI Impact: Reduces screen media changeout time by approximately 40%, lowering labor costs.

Centralized Greasing System | Technical Basis: Automated lubricant distribution from a single point to all major bearings. | Operational Benefit: Ensures consistent lubrication of critical components during operation, extending bearing life. | ROI Impact: Cuts manual greasing labor by 80% and can reduce premature bearing failure incidents by an estimated 30%.

HighStrength Chassis Fabrication | Technical Basis: CADoptimized chassis constructed from T1 steel with robotic welding. | Operational Benefit: Provides exceptional structural integrity to handle dynamic loads over a 20+ year lifespan with minimal frame fatigue. | ROI Impact: Lowers lifetime cost of ownership by reducing need for structural repairs or reinforcements.

VariableSpeed Feeder Control | Technical Basis: Frequency drivecontrolled apron or vibrating feeder. | Operational Benefit: Allows operators to precisely match feed rate to crusher capacity in realtime based on power draw. | ROI Impact: Prevents crusher choking or running empty; improves overall energy efficiency per ton by up to 8%.

Dust Suppression Integration Points | Technical Basis: Preinstalled piping manifolds and nozzle mounting pads at transfer points. | Operational Benefit: Simplifies connection to water supply for effective dust control from day one of operation. | ROI Impact: Facilitates compliance with site environmental regulations; reduces wear on components from abrasive dust.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Commercial Crushing Solution | Advantage (% Improvement) |
| : | : | : | : |
| Crusher Wear Part Life (Mn18) | ~450,000 tons | ~600,000 tons| +33% |
| Screen Bearing Replacement Interval| ~3,000 hours| ~4,500 hours| +50% |
| Plant Setup Time (Modular) | 57 days| 34 days| 40% |
| Power Consumption per Ton Output| Varies widely; baseline = X kWh/t| Field data shows X0.5 kWh/t average reduction.| 5% to 12% |
| Overall Plant Availability Target| ~85%88% availability target.| Designforreliability supports >92% availability target.| +4% to +7% |

5.TECHNICAL SPECIFICATIONS

Capacity/Rating: Configurable from 200 TPH to over 800 TPH final product output.
Power Requirements: Primary plant electrical demand ranges from 350 kVA to 800 kVA depending on configuration; all motors are IEC standard with IP66 protection.
Material Specifications: Primary wear parts available in Mn18%, Mn22%, or highchrome iron alloys; conveyor belts are EP630/4 minimum with vulcanized splices.
Physical Dimensions (Example Modular Jaw Plant): Feed Hopper (12m³), Jaw Crusher Module (L10m x W3m x H4m), Discharge Conveyor (L24m).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust sealing suitable for operation in environments with up to 95% relative humidity (noncondensing).

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: A regional quarry needed to increase production of ASTM 57 stone by 60% but had space constraints preventing a traditional plant expansion.
Solution: Implementation of a threestage modular commercial crushing plant featuring a primary jaw crusher secondary cone crusher tertiary cone crusher with a closedcircuit screening tower.
Results: Achieved target tonnage within the existing footprint; precise chip control yielded a 98% firstpass specification rate reducing recirculating load Project payback was achieved in under 18 months through increased sales volume

Urban Recycling & C&D Processing

Challenge A recycling contractor faced high maintenance costs and excessive downtime when processing contaminated demolition concrete with rebar
Solution Deployment of a heavyduty impactorbased commercial crushing system equipped with an electromagnetic separator over the discharge conveyor
Results The impactor's open rotor design handled slab material efficiently while the magnet removed ferrous contaminants Results showed a reduction in downstream crusher damage incidents by over70and produced cleanhighvalue RCA recycled concrete aggregate

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around throughput capacity and automation level:
Tier I High Efficiency Core Plant includes primary secondary crushing basic screening essential conveyors
Tier II Advanced Production Plant adds automated product sorting tertiary crushing stage advanced dust suppression
Tier III Turnkey Processing System integrates full electrical control PLC system automated wear monitoring remote diagnostics

Optional Features Radial stacker conveyors wash plants for manufactured sand hybrid diesel electric drive options sound attenuation enclosures

Service Packages Proactive maintenance plans include scheduled inspections parts kits priority support Extended warranties are available covering major structural components Financing Options Flexible commercial leasing structures operating leases capital leases project financing solutions are available through accredited partners

8 FAQ

Q What if my feed material hardness changes frequently?
A Our commercial crushing plants feature easily adjustable crusher settings screen deck angles The variable speed feeder allows quick optimization ensuring consistent product despite varying feed

Q How does this equipment integrate with my existing conveyors or screens?
A Plants are engineered with industry standard transfer heights belt widths Our engineering team can provide interface drawings ensure compatibility during pre purchase planning

Q What is the typical lead time from order commissioning?
A For standard modular configurations lead time ranges between weeks Custom engineered solutions require longer detailed project timelines provided upon application review

Q Are performance guarantees offered?
A Yes guaranteed minimum throughput capacity based on defined feed material specifications formalized within the sales contract We conduct joint commissioning tests verify performance

Q What operator training technical support provided?
A Comprehensive onsite training included covering safe operation routine maintenance troubleshooting Dedicated technical support line provides access factory engineers