1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and engineering contractors, inefficient material processing directly impacts profitability. Common challenges include:

High Downtime for Maintenance: Frequent liner changes, bearing failures, and unplanned stops for crushers and screens can consume hundreds of production hours annually.
Inconsistent Product Gradation: Outdated or poorly matched equipment leads to offspec aggregate, causing product rejection, reprocessing costs, and lost revenue.
Excessive Fuel & Power Consumption: Older crushing and screening plants often operate at fixed, inefficient rates, wasting significant energy on partial loads.
Rapid Wear Part Degradation: Abrasive materials can decimate standard components, leading to exorbitant and frequent replacement part expenditures.
Inflexible Setup for Changing Feed Stock: Static systems cannot adapt to variable feed size or material hardness without manual reconfiguration, causing bottlenecks.

Is your current equipment portfolio equipped to minimize these costs while maximizing throughput and product quality? The solution lies in specifying modern, purposeengineered crushing and screening equipment.

2. PRODUCT OVERVIEW

This portfolio encompasses advanced primary, secondary, and tertiary crushing stations paired with highefficiency vibrating screens. These systems are engineered for the continuous reduction and classification of aggregate, ore, and recycled construction materials.

Operational Workflow:
1. Primary Reduction: Feed material is introduced to a robust jaw or gyratory crusher for initial size reduction.
2. Primary Screening: Scalping screens remove fines and bypass material prior to secondary crushing, improving efficiency.
3. Secondary/Tertiary Crushing: Cone or impact crushers further process material to the target size range.
4. Final Classification: Multideck screens precisely separate crushed product into specified grades (e.g., base course, chips, sand).
5. Stockpiling & Recirculation: Onspec material is conveyed to stockpiles; oversize is automatically recirculated back into the circuit.

Application Scope: Stationary plants for quarries and largescale mining; Trackmounted mobile units for multisite contracting; Skidmounted modules for semipermanent installations.

Key Limitations: Maximum feed size and material abrasiveness (Ai) dictate crusher selection. Extremely sticky or highmoisture feeds may require prescreening or washing attachments not covered in a standard dry system.

3. CORE FEATURES

Hydroset CSS Adjustment | Technical Basis: Hydraulic piston supporting the main shaft | Operational Benefit: Closedside setting (CSS) can be adjusted under load in under one minute for realtime product control. | ROI Impact: Eliminates production stops for manual shim adjustments, saving an estimated 30+ hours of downtime per year.

Direct Drive Crusher & Screen Motors | Technical Basis: Elimination of Vbelts and sheaves via direct coupling | Operational Benefit: Increased power transmission efficiency (up to 99%) and reduced maintenance points. | ROI Impact: Lowers energy consumption by approximately 58% compared to traditional beltdriven systems.

Modular Screen Media System | Technical Basis: Rubberclad steel frame with polyurethane or wire cloth inserts | Operational Benefit: Panels can be replaced by a twoperson crew in under two hours without welding. | ROI Impact: Reduces screen deck changeout time by up to 70%, minimizing production interruption.

PLCBased Plant Automation | Technical Basis: Centralized programmable logic controller with touchscreen HMI | Operational Benefit: Monitors amp draw, pressure, temperature; allows sequence start/stop and remote troubleshooting. | ROI Impact: Optimizes throughput balance between crushers and screens; prevents catastrophic damage through automated shutdowns.

Tier 4 Final / Stage V DieselElectric Option | Technical Basis: Diesel engine drives generator powering all electric motors on mobile plants | Operational Benefit: Compliant operation in regulated regions with significantly lower fuel consumption than hydraulic drive systems. | ROI Impact: Field data shows a 2030% reduction in fuel costs on comparable mobile crushing contracts.

Advanced Wear Part Metallurgy | Technical Basis: Austenitic manganese steel with patented carbide infusion processes | Operational Benefit: Crusher jaws and cones maintain profile longer under abrasive conditions. | ROI Impact: Extends wear life by 1525%, directly reducing costperton for consumables.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing & Screening Solution Documented Advantage |
| : | : | : |
| Tons per Hour (TPH) per kW/h | Varies by material; baseline established from industry averages. Up to 5% improvement in specific energy consumption through optimized kinematics & direct drive systems. |
| Mean Time Between Failure (MTBF) Bearings| ~2,0003,000 hours in primary crushers under heavy load.| Engineered bearing housing design & automated lubrication extend MTBF to over 4,000 hours in documented cases.| Upwards of 33% improvement|
| Screen Deck ChangeOut Time| 812 hours for a tripledeck screen with welded panels.| Modular system allows complete panel replacement in under 4 hours.| Up to 67% faster|
| Product Shape (Cubicity) Index| Secondary cone crushers may produce up to 35% flaky content in certain applications.| Multilayer crushing chamber technology promotes interparticle crushing.| Improvement of up to 15% in cubicity index|
| Setup / Teardown Time (Mobile Plant)| Full plant relocation can take a full shift (8 hrs).| Integrated hydraulic folding conveyors & quickdisconnect walkways streamline the process.| Reduction to approximately 5 hours|

5. TECHNICAL SPECIFICATIONS

Capacity Range: Mobile plants from 200 – 550 tonnes per hour (TPH); Stationary plants configured from 500 – over 2,500 TPH.
Power Requirements: Electric drive options from 150 kW – 800 kW total installed power per major crushing stage.
Material Specifications: Crushers engineered for compressive strength up to 400 MPa; Wear components rated for abrasion index (Ai) up to 0.6.
Physical Dimensions (Mobile Jaw Unit Example): Transport length ~16m; Working length ~20m; Height ~4m; Operating weight ~55 tonnes.
Environmental Operating Range: Standard units rated for 20°C to +40°C ambient temperature; Dust suppression systems maintain compliance at feed points; Highaltitude packages available for operation above 2,500m.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Challenge

Challenge A quarry needed to increase production of railway ballast (40mm +20mm chip) by 40% without expanding their permitted footprint or primary crusher.
Solution Implementation of a tertiary cone crusher circuit with a doubledeck rinsing screen was integrated downstream of existing secondary crushers.
Results The dedicated circuit allowed precise control over the final crushing stage. Ballast production increased by 42%, with cubicity exceeding rail specification by 12%. Overall plant yield improved due to reduced recirculating load.

Urban Concrete Recycling Contract

Challenge A demolition contractor won a major city redevelopment project but faced strict noise/dust limits and required highpurity (<1% contaminant) recycled aggregate from mixed C&D waste.
Solution A trackmounted jaw crusher paired with a closedcircuit impactor and tripledeck screen was deployed onsite.
Results The mobile setup eliminated trucking raw debris across the city. The final screening stage achieved 98% purity on recycled concrete aggregate (19mm). Onsite processing reduced project haulage costs by an estimated 35%.

7 COMMERCIAL CONSIDERATIONS

Pricing Tiers: Solutions range from singlemachine mobile units ($500k $1.2M USD) to complete stationary plant engineering packages ($3M $15M+ USD).
Optional Features / Upgrades: Advanced dust encapsulation kits, automatic grease lubrication systems,
remote telemetry packages,
onboard weighing systems,
and hybrid dieselelectric drive options are available at additional cost but offer demonstrable payback periods.
Service Packages: Tiered plans are offered from basic scheduled maintenance support
to comprehensive fullcostperton contracts that include all wear parts,
labor,
and planned rebuilds,
providing predictable operational expenditure.
Financing Options: Equipment can be acquired through capital purchase,
operating lease,
or finance lease structures tailored
to balance sheet requirements;
rentaltoown programs are also available
for qualifying projects with shorterterm horizons

8 FAQ

Q What level of foundation preparation is required for your stationary crushing plants?
A Our engineered foundations are designed based on your specific soil report
and equipment loading data;
we provide full civil drawings
as part of the plant package
to ensure stable,
longterm operation

Q How does your automation system integrate with my existing plant PLC or SCADA?
A The standard control system communicates via Modbus TCP/IP protocol;
our engineering team will work during commissioning
to establish necessary data points
for centralized monitoring

Q What is the typical lead time from order placement
to commissioning?
A For standard configured mobile units,
lead time averages between 16 24 weeks;
fully customized stationary plants require detailed engineering
with lead times of 9 14 months

Q Are performance guarantees offered?
A Yes;
we provide written guaranteed capacity,
power consumption,
and wear part life metrics based on your specific feed material analysis during the proposal stage

Q What training is provided for our operations
and maintenance teams?
A We include comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting guides;
additional simulatorbased training is available as an option