1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, inefficient material processing directly impacts profitability. Common challenges include:
Unscheduled Downtime: Component failures in harsh environments lead to costly, unplanned stoppages. Every hour of lost production represents significant revenue forfeited.
High Maintenance Costs: Frequent wear part replacement and laborintensive servicing schedules consume both budget and manhours.
Inconsistent Product Quality: Variable feed material can cause fluctuations in final aggregate size, leading to product rejection or reprocessing.
Rising Fuel & Power Expenses: Inefficient crushing and screening circuits consume excessive energy, a major and volatile operational cost.
Rigid Plant Configuration: Fixed systems cannot adapt to changing project specs or site conditions, limiting your contract versatility.

Is your current equipment portfolio equipped to address these pressures? The solution lies in specifying machinery engineered for total cost of ownership, not just initial purchase price.

2. PRODUCT OVERVIEW

This product line encompasses highcapacity, trackmounted or wheeled mobile crushing and screening plants designed for commercialscale quarrying, mining, and large construction projects. These integrated systems process raw feed material (e.g., blasted rock, demolition concrete) into precisely sized commercial aggregates.

Operational Workflow:
1. Primary Crushing: Large feed material is reduced by a robust jaw or impact crusher.
2. Primary Screening & Conveying: A firststage screen separates sized material from oversize, which is conveyed for further reduction.
3. Secondary/Tertiary Crushing: Oversize material is directed through cone or impact crushers for finer reduction.
4. Final Screening: Multipledeck screens classify crushed material into specified end products (e.g., ¾” chip, base course, manufactured sand).
5. Stockpiling: Radial conveyors stack finished products for loadout.

Application Scope & Limitations:
Scope: Ideal for hightonnage aggregate production, C&D recycling operations, and primary reduction in mining. Suited for both greenfield sites and established pits.
Limitations: Not designed for abrasive metal ores without specific liner configurations. Maximum feed size and hardness are constrained by modelspecific engineering limits.

3. CORE FEATURES

Direct Drive Crusher System | Technical Basis: Eliminates Vbelts & associated components | Operational Benefit: Reduces power transmission losses and removes a frequent failure point | ROI Impact: Field data shows up to 8% lower fuel consumption and 15% less maintenance time versus traditional drives.

Tier 4 Final / Stage V DieselElectric Propulsion | Technical Basis: Diesel engine powers generator supplying electricity to all plant motors | Operational Benefit: Significant fuel savings at partial loads; enables singleengine operation | ROI Impact: Industry testing demonstrates fuel savings of 2030% over direct hydraulic drives in typical duty cycles.

HeavyDuty Feeder with Integrated PreScreen | Technical Basis: Grizzly feeder removes fines prior to primary crusher | Operational Benefit: Reduces crusher cavity wear and prevents chamber packing | ROI Impact: Extends wear part life by an estimated 25%, decreasing costperton.

Centralized Greasing & PLC Control System | Technical Basis: Automated lubrication points with machine health monitoring via programmable logic controller | Operational Benefit: Ensures bearing longevity; allows operators to diagnose issues from ground level | ROI Impact: Minimizes lubricationrelated failures; reduces service time by an estimated 40%.

Hydraulic Setting Adjustment (HSA) | Technical Basis: Crusher gap adjustment via hydraulic cylinders rather than mechanical shims | Operational Benefit: Allows closedside setting changes in under 5 minutes without stopping the crusher | ROI Impact: Enables rapid product size changes, increasing plant flexibility and utilization.

Folding Side Conveyors & Compact Transport Mode | Technical Basis: Hydraulically folded conveyors and crusher components for road transport | Operational Benefit: Reduces mobilization/demobilization time from days to hours | ROI Impact: Cuts relocation costs by up to 60%, allowing more competitive bidding on dispersed projects.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | This Commercial Crushing & Screening Solution | Advantage (% Improvement) |
| : | : | : | : |
| Fuel Consumption (liters/ton) | Based on direct hydraulic drives on similar duty cycle. ~2.1 L/tonne average. ~1.6 L/tonne average based on field reports from comparable sites.| ~23% improvement |
| Wear Part Cost ($/ton) Varies by material abrasiveness.| $0.85 $1.10 / ton for granite.| Optimized kinematics & liner materials target $0.70 $0.95 / ton.| Up to 15% reduction |
| Mean Time Between Failures (MTBF) Critical Components| ~450 operating hours.| Engineered for >600 operating hours.| ~33% increase |
| Setup / Teardown Time (for relocation)| 23 days with crane support.| 95%.| ~47% more saleable product |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Modeldependent; ranges from 250 to over 600 tonnes per hour in closedcircuit configuration with typical hard rock (approx. UCS 150250 MPa).
Power Requirements: Primary plant power provided by a single EPA Tier 4 Final / EU Stage V compliant diesel engine, typically rated between 350 550 kW.
Material Specifications: Crusher jaws/mantles fabricated from highgrade manganese steel (1822%). Wear plates constructed from AR400 steel throughout highabrasion zones.
Physical Dimensions (Operating): Variable by model; approximate footprint of a midrange unit is 18m (L) x 5m (W) x 5m (H). Transport dimensions comply with local road regulations without permits in most regions.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C (13°F to +113°F). Dust suppression system standard; sound enclosures available to reduce operational dB levels.

6. APPLICATION SCENARIOS

LargeScale Quarry Expansion | Challenge: A granite quarry needed to increase output by 35% without expanding its fixed plant footprint or significantly adding crew. Mobilization between multiple faces was slow and costly.| Solution: Deployment of two trackmounted commercial crushing and screening plants with direct drive crushers and onboard prescreens.| Results: Plants relocated three times within the pit over six months. Achieved a net output increase of 38%, with a recorded 21% lower fuel cost per ton compared to the older fleet they replaced.

Major Infrastructure Project Recycling| Challenge: A contractor winning a highway contract was mandated to recycle all existing pavement onsite but faced strict noise/dust regulations near residential areas.| Solution: A closedcircuit commercial impact crushing & screening plant equipped with advanced dust encapsulation and noisereducing packages was selected.| Results:The plant processed over 500,000 tons of reclaimed asphalt pavement (RAP) and concrete meeting all environmental compliance standards.The produced spec aggregate was reused as base material,saving an estimated $12/ton in virgin aggregate purchaseand haulage costs.

7.COMMERCIAL CONSIDERATIONS

Commercial crushingand screening equipment pricing is structured around configurationand capacity:

Pricing Tiers:

Entry Commercial Tier ($750k $1.2M): Highcapacity jaw plants or compact impactor setups for dedicated mediumduty applications.
MidRange Production Tier ($1 .3M $2M): Full closedcircuit cone or hybrid plants with advanced prescreening,favoredfor highvolume aggregate production.
Premium Configurable Tier ($2M+): Fully customizable multistage plantswith specializedcrushers( e.g.,for manufactured sand),extended conveyors,and automation suites.

Optional Features: Advanced dust suppression systems,coldweather start packages,magnetic separators ,secondary recycling modules,and telematics/GPS tracking integration are available at additional cost .

Service Packages typically include scheduled maintenance plans ,wear part kits,and remote diagnostic support.Financing options encompassoperating leases,tailored rentaltoown agreements,and projectbased financing through partner institutions .

8.FAQ

Q:What is the lead timefor deliveryof a configuredcommercialcrushingplant?
A :Lead times varyby model complexityand current global demand .Standard configurations typicallyrange from20to36weeksfrom order confirmation .Your sales engineer will providea projectspecific timeline .

Q :Can this equipment integratewith our existingconveyorsand screens?
A :Yes .Theseplantsare designedwith standardizeddischarge heightsand control system protocolsto interfacewith thirdpartyequipment .Our engineeringteamcan reviewyour layoutto ensure compatibility .

Q:What does the recommendedpreventive maintenanceschedule involve?
A:A comprehensivescheduleis provided ,detailingdaily ,weekly ,monthly ,and annual servicepoints .It focuseson greasing intervals ,wear measurement ,and system diagnostics .Adherenceis criticalto maintainingwarranty coverage .

Q :Are operator trainingandsupportincluded ?
A :Yes .A multidayonsite trainingprogramfor youroperatorsand maintenancecrewis includedwith purchase .This coverssafe operation ,basic troubleshooting,and daily maintenance procedures .

Q:What warrantyperiodis offered ?
A:The standardwarrantyprovides24monthsor2 ,000operatinghours(whichever comes first )on themachine structureand12months/1 ,500hourson wear parts .Extendedwarrantyoptionsare available .

Q :How do you quantifythe potentialROIfor my specificoperation ?
A :Our applicationengineerswill analyzeyour currentcostperton data(maintenance,fuel,wear parts,downtime )and modelexpectedperformancebasedon your feedmaterialand targetoutputs topresenta detailedROI projection .

Q:What mobilizationequipmentis required ?
A:The trackmountedplantsare selfpropelledwithin the site.Wheeled versionsor individualmodulesrequirelowboy transport.For setup,a standard50ton mobile cranecan typicallyhandleall liftingrequirements ;specific lift plansare provided