1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, the crushing and screening circuit is often the source of critical bottlenecks. Common challenges include:
Unscheduled Downtime: Frequent mechanical failures and lengthy component changes can halt your entire production line, costing thousands per hour in lost output.
Inconsistent Product Gradation: Offspec material leads to rejected loads, reprocessing costs, and dissatisfied clients, directly impacting profitability.
High Maintenance Labor & Parts Costs: Complex, inaccessible equipment designs require excessive manhours for routine servicing and drive up inventory costs for wear parts.
Energy Inefficiency: Older or poorly designed equipment consumes excessive power per ton of material processed, a fixed cost that severely impacts operating budgets.
Rigid Plant Configuration: Inflexible equipment that cannot adapt to changing feed material or final product requirements limits your ability to capitalize on new contracts.

Is your current setup equipped to handle variable feed stock efficiently? How much revenue are you losing to maintenance cycles and energy waste? The solution lies in specifying precisionengineered crushing and screening equipment designed for reliability and total cost of ownership.

2. PRODUCT OVERVIEW

Our modular crushing and screening equipment encompasses a coordinated system of primary jaw crushers, secondary/tertiary cone or impact crushers, and multideck vibrating screens. This system is engineered for the continuous reduction and classification of aggregate, ore, and recycled materials.

The operational workflow is optimized for linear efficiency:
1. Primary Reduction: ROM (RunofMine) or quarryrun material is fed into a robust jaw crusher for initial size reduction.
2. Secondary/Tertiary Crushing: Material is conveyed to cone or impact crushers for further refinement to the desired intermediate size.
3. Sizing & Classification: Crushed material is directed to vibrating screens where it is accurately separated into specified product fractions.
4. Recirculation & Stockpiling: Oversize material is recirculated back into the circuit for recrushing, while onspec product is conveyed to designated stockpiles.

Application scope includes stationary plants and trackmounted mobile units for quarrying, mining, construction demolition recycling, and industrial minerals. Key limitations are defined by feed size hardness (abrasion index) and required final product specifications, which determine the optimal crusher chamber configuration and screen media selection.

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Computeroptimized kinematics & cavity profile | Operational Benefit: Delivers consistent output gradation with reduced slabby or elongated product | ROI Impact: Minimizes recrush cycles, improving throughput by up to 15% based on application.

Centralized Greasing & Hydraulic Systems | Technical Basis: Singlepoint lubrication rails and PLCcontrolled hydraulic adjustment | Operational Benefit: Enables safe, rapid setting changes and routine maintenance from ground level in under 10 minutes | ROI Impact: Reduces service downtime by approximately 30% and lowers labor cost per maintenance event.

HeavyDuty Vibrating Screen with BoxSection Beams | Technical Basis: Finite Element Analysis (FEA)designed chassis with highstress reinforcement | Operational Benefit: Eliminates structural fatigue cracking under highcycle loading with heavy abrasive feeds | ROI Impact: Extends structural life beyond industry average, deferring major capital replacement costs.

Tier 4 Final / EU Stage V Compliant Power Units | Technical Basis: Advanced diesel engines coupled with efficient hydraulic drives | Operational Benefit: Provides full operational power while significantly reducing fuel consumption per ton of material processed | ROI Impact: Field data shows a 1218% reduction in fuel costs compared to previous generation power plants.

Modular Conveyor & Walkway System | Technical Basis: Standardized bolttogether design with safetyintegrated guarding | Operational Benefit: Expedites plant installation, reconfiguration, or relocation while ensuring compliance with site safety standards | ROI Impact: Reduces plant commissioning time by up to 25%, accelerating project revenue generation.

Smart PLC Control System with Telemetry | Technical Basis: Industrialgrade programmable logic controller with remote monitoring capability | Operational Benefit: Provides realtime data on production rates, power draw, and operational faults for proactive management | ROI Impact: Enables predictive maintenance scheduling, preventing catastrophic failures and optimizing component life.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing & Screening Solution Documented Advantage |
| : | : | : |
| Crusher Wear Part Life (Abrasive Granite) Manganese Jaw Plate Life Expectancy ~6080k MT Our Solution Achieves >110k MT +37% Improvement |
| Screening Efficiency (5mm separation) Typical Efficiency ~8590% Our Solution Maintains >94% +5% Improvement (Reduces Recirculating Load) |
| Average Time for Liner Change (Cone Crusher) Estimated 68 hours Our Process Completes in <4 hours 50% Downtime Duration |
| Plant Mobility / Setup Time (TrackMounted Plant) Full Setup in ~12 Days Full Setup in <6 Hours 75% Deployment Time |
| Fuel Consumption (per 100 tons processed) Baseline Reference Our Documented Consumption 15% Improvement |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 TPH to over 800 TPH stationary plants; Mobile units from 200 TPH to 400 TPH.
Power Requirements: Electric motor drives from 75 kW to 400 kW per major crusher unit. Dieselhydraulic mobile plants feature engines from 350 kW to 500 kW.
Material Specifications: Fabricated from highyield strength steel (min. S355J2). Crusher wear parts in premium manganese steel (18%22%). Screen decks available in woven wire, polyurethane, or rubber modular panels.
Physical Dimensions (Mobile Jaw Crusher Example): Working length ~17m; Height ~4m; Width ~3m; Operating weight ~45 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression systems standard. Can be configured for highaltitude operation.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Challenge

A large granite quarry needed to increase production by 40% without expanding its physical footprint or significantly adding staff.
We implemented a threestage stationary crushing plant featuring a largecapacity jaw crusher,
a highspeed cone crusher for chip production,
and two tripledeck banana screens.
The new plant achieved a sustained throughput of 650 TPH,
with improved product shape meeting stringent asphalt chip specifications,
and reduced energy consumption per ton by approximately
11%.

Urban Construction & Demolition Recycling Challenge

A contractor processing C&D waste faced excessive downtime due to uncrushable contaminants
and needed a cleaner final aggregate product for resale.
We supplied a trackmounted impact crusher with an integrated prescreening module
and an overband magnet.
The prescreener removes fines before crushing,
reducing wear,
while the powerful impactor handles reinforced concrete efficiently.
Results included a
30%
reduction in wear part costs,
production of a highly marketable clean aggregate,
and the ability to relocate the unit between city sites within a single workday.

7. COMMERCIAL CONSIDERATIONS

Our crushing solutions are offered across several tiers:
Standard Configuration Tier: Highreliability core systems optimized for common materials like limestone and recycled concrete. Focus on maximum value.
HighAbrasion Tier: Upgraded specifications including thicker wear liners,
premium bearing packages,
and enhanced guarding for processing abrasive materials like granite or basalt.
Fully Automated Tier: Incorporates advanced PLC control with automatic setting regulation,
camerabased feed monitoring,
and full telematics integration for fleet management.

Optional features include dust suppression cannons,
secondary scrap metal magnets,
onboard weighing systems,
and extraheavyduty conveyors.

We support our equipment with tiered service packages from basic warranty extension
to comprehensive planned maintenance agreements including parts supply
and regular health inspections.Financing options include conventional capital purchase,
operational leasing structures tailored to seasonal work,
and rentaltoown programs designed to preserve capital liquidity.

8. FAQ

Q1: Is your equipment compatible with our existing conveyors and feeders?
Yes.Modular design allows integration with thirdparty upstream feeding
and downstream stockpiling systems.We provide interface drawings
and can supply adapter sections as needed during commissioning.

Q2:What is the typical lead time from order placement until commissioning?
For standard mobile units lead time averages between
1216 weeks.For customconfigured stationary plants detailed project scheduling will be provided upon specification finalization typically ranging from
2030 weeks depending on complexity

Q3:What training do you provide for our operations team?
We include comprehensive onsite operator training covering daily startup/shutdown procedures routine maintenance safety protocols basic troubleshooting This training occurs during commissioning

Q4:What are your payment terms?
Standard commercial terms involve an order deposit milestone payments tied factory acceptance shipping balance due prior shipment Custom financing arrangements through partners can structure payments differently

Q5:What guarantees do you offer on wear part life?
Wear part life depends entirely on specific material characteristics abrasiveness We provide documented performance expectations based your feed analysis but guarantees are tied measurable material properties not fixed time periods

Q6:What level of engineering support do you provide during plant layout planning?
Our technical team provides foundational layout drawings flow diagrams foundation load data electrical load lists For turnkey projects we offer full civil electrical integration design services as separate scope work

Q7:What spare parts inventory do you recommend we hold onsite?
We develop recommended critical spares list based intended application common items include set hydraulic hoses screen tension mats selection belt scrapers essential sensors filters maintain operations between planned service intervals