1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? In crushing and screening, common challenges directly impact your bottom line. Consider these frequent scenarios:
Unscheduled Downtime: Component failures in critical crushers or screen decks halt entire processing lines, costing thousands per hour in lost production and labor.
High Maintenance Costs: Frequent bearing changes, wear part replacement, and manual adjustments consume both budget and maintenance team hours.
Inconsistent Product Gradation: Outofspec aggregate or mineral product leads to rejected loads, contract penalties, and wasted raw material.
Inefficient Fuel/Power Consumption: Older or poorly configured equipment operates at low efficiency, with a significant portion of energy costs not translating to usable throughput.
Rapid Wear in Abrasive Applications: The financial burden of constantly replacing liners, screens, and blow bars in hard rock or slag processing is substantial.

What if your primary crushing station could deliver more tons between service intervals? How would predictable output gradation improve your downstream operations? The solution lies in selecting crushing and screening equipment engineered to address these exact operational and financial pressures.

2. PRODUCT OVERVIEW: MOBILE TRACKMOUNTED CRUSHING & SCREENING PLANT

This product category refers to a selfcontained, trackmounted system that integrates primary crushing, secondary/tertiary crushing, and screening modules into a single mobile unit. It is designed for onsite processing of quarried rock, recycled concrete & asphalt (RCA), and natural stone.

Operational Workflow:
1. Feed & Primary Crushing: Raw material is loaded via excavator or wheel loader into a vibrating grizzly feeder (VGF), which bypasses fines and directs oversize to the robust jaw crusher for initial size reduction.
2. Secondary Processing & Screening: Crushed material is conveyed to a cone crusher for further refinement. The output is then fed onto a highcapacity multideck screenbox.
3. Product Sorting & Stockpiling: The screen separates material into 35 specified grades (e.g., base course, drainage stone, chips). Oversize is recirculated via closedcircuit conveyors for recrushing, while onspec products are stockpiled by radial stackers.

Application Scope: Ideal for mediumtolarge scale contract crushing requiring relocation between sites (quarries, demolition yards, large civil works projects). Excellent for producing spec aggregate from virgin rock or recycled materials.

Limitations: Not suitable for underground mining or fixedplant installations requiring extreme longevity over mobility. Maximum feed size and hardness are constrained by the integrated primary crusher model.

3. CORE FEATURES

Direct Drive Crushers | Technical Basis: Elimination of Vbelts and associated components | Operational Benefit: Increased power transmission efficiency (up to 96%) and reduced maintenance points | ROI Impact: Lower fuel consumption per ton crushed and reduced risk of downtime from belt failure/slippage.

Independent PreScreen | Technical Basis: Vibrating grid section mounted before the crusher inlet | Operational Benefit: Removes fines and sticky material prior to crushing chamber entry | ROI Impact: Reduces crusher cavity wear by up to 30% and prevents chamber packing, maintaining optimal throughput.

Hydraulic Adjustment & Clearing | Technical Basis: Integrated hydraulic rams for CSS adjustment and uncrushable release | Operational Benefit: Operators can adjust product size or clear blockages in minutes from ground level | ROI Impact: Minimizes downtime for routine adjustments by over 70% compared to manual shim systems.

Tier 4 Final / Stage V DieselElectric Propulsion | Technical Basis: Diesel engine drives generators powering electric motors on tracks, feeders, and conveyors | Operational Benefit: Significant fuel savings (field data shows 1525%), quieter operation, and precise control | ROI Impact: Direct reduction in operating cost per ton with compliance in all regulatory zones.

PLCBased Intelligent Control System | Technical Basis: Programmable Logic Controller with color touchscreen interface | Operational Benefit: Monitors production rates, CSS settings, power draw, and alerts operators to anomalies | ROI Impact: Enables datadriven optimization for peak efficiency and provides diagnostic logs to preempt failures.

HeavyDuty Roller Bearing Construction | Technical Basis: Largediameter spherical roller bearings on eccentric assemblies | Operational Benefit: Supports high radial and thrust loads with superior heat dissipation | ROI Impact: Extends bearing service life by 23x under severe duty cycles, deferring major overhaul costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Mobile TrackMounted Crushing & Screening Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Fuel Consumption (L/ton) | Hydraulic directdrive systems | Dieselelectric drive with loadsensing hydraulics| Up to 25% improvement |
| Wear Part Changeout Time (Jaw Liners)| Manual removal with overhead crane assist| Hydraulicassisted wedge system with lifting tool| Approximately 50% faster |
| Setup / Teardown Time (between sites)| Multiple independent units requiring alignment| Singleunit integrated plant with hydraulic folding conveyors| Up to 40% faster mobilization |
| Product Gradation Consistency (± % from target)| Manual CSS adjustment based on periodic sampling| Remote CSS adjustment via PLC with realtime feedback loop| Consistency improved by ~60% |

5. TECHNICAL SPECIFICATIONS

Capacity/Throughput: Up to 450 tonnes per hour (TPH), dependent on feed material density & hardness.
Primary Crusher: Jaw Crusher, feed opening up to 1m x 800mm.
Secondary Crusher: Cone Crusher with multiple crushing chamber options.
Screenbox: Tripledeck vibrating screen; area up to 7m² per deck.
Power Unit: EPA Tier 4 Final / EU Stage V diesel engine rated at 350 kW.
Material Specifications: Crusher liners manufactured from manganese steel (1822%). Chassis constructed from hightensile strength steel (S690QL).
Physical Dimensions (Operating): Length ~27m; Width ~4m; Height ~5m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system fitted as standard.

6. APPLICATION SCENARIOS

Recycled Concrete Aggregate (RCA) Production Challenge:

A demolition contractor faced high landfill fees and missed revenue opportunities from concrete waste. Onsite crushing was hampered by rebar contamination causing frequent downstream blockages and inconsistent final product quality affecting sales price.

Solution:

Implementation of a mobile trackmounted plant featuring an electromagnetic overband magnet on the main conveyor and a robust jaw crusher capable of processing reinforced concrete chunks.

Results:

The plant processed over 250k tons of demolition concrete annually. Rebar removal exceeded 98%, eliminating blockagerelated downtime. The consistent RCA product commanded a 20% higher market price than uncertified material while eliminating $150k+ in annual tipping fees.

Granite Quarry Contract Crushing Challenge:

A quarry operator needed flexible capacity for a new granite deposit without capital investment in fixed infrastructure. Key concerns were extreme abrasiveness wearing out components rapidly and maintaining tight product specifications for a highway construction contract.

Solution:

Deployment of a tracked coneandscreen plant equipped with specialized abrasivegrade liners in the cone crusher an advanced automated control system that maintained closedside setting (CSS).

Results:

The plant achieved a sustained throughput of 380 TPH of hard granite. Wear life on cone mantles increased by approximately 40% compared to previous equipment used on the same material. Product gradation stayed within contract specifications for over 95% of sampled loads avoiding any penalties

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are typically structured around capacity core machine configuration:

Base Configuration Tier ($1M $1M): Includes standard jaw/cone/screen combination standard dust suppression basic control system
HighCapacity Tier ($1M $1M): Features larger crushers additional prescreen option extended conveyors enhanced wear packages
Specialized Application Tier ($1M+): Customized with features like rock hammers grizzly bypass systems advanced air filtration

Optional features include onboard water pumps for dust suppression wireless remote control radial side conveyor for secondary stockpiling extra heavyduty wear liners

Service packages range from basic warranty extensions(12 months/2000 hours)to comprehensive fullmaintenance contracts covering all parts labor scheduled servicing

Financing options available include equipment leasing capital loans rentaltoown agreements tailored to match project cash flow cycles

8 FAQ

Q What is the lead time from order commissioning?
A Standard configurations typically have lead time of months Customized units may require months depending specifications Current production schedules confirmed upon inquiry

Q Is this equipment compatible with existing support machinery?
A Yes These plants are designed work seamlessly with standard excavators wheel loaders haul trucks Industry standard interfaces ensure compatibility

Q How does this solution impact my site manpower requirements?
A The centralized PLC control system automated functions allow single operator manage entire crushing screening process effectively reducing required personnel compared multiunit setups

Q What commercial terms are available?
A We offer several structures including outright purchase finance lease operating lease Longterm rental agreements also available provide maximum flexibility

Q What does implementation look like onsite?
A Delivery includes supervised commissioning operator training period Our technicians ensure plant operational according specifications before handover Full documentation provided