1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant is a critical asset, yet standard configurations often introduce costly inefficiencies. Common challenges include:
Inconsistent Feed & Downtime: Unstable feed size or material hardness fluctuations cause frequent chokeups in secondary/tertiary stages, leading to unplanned stoppages. Industry data indicates that each hour of unscheduled downtime can cost over $1,200 in lost production and labor.
High Operational & Maintenance Costs: Premature wear on crusher liners and conveyor components due to improper crushing chamber design or inadequate material flow control drives up spare parts consumption and maintenance labor.
Poor Final Product Shape & Yield: Inability to precisely control particle shape and gradation results in a lower percentage of premium, highvalue aggregates, directly impacting revenue per ton.
Complex Setup & Inflexibility: Modular plants that require excessive onsite assembly or lack the configurability to switch between different aggregate specifications limit your responsiveness to market demands.

Is your current solution equipped to handle variable feed materials while maintaining a consistent 300tph output with optimal cubicle product shape? Can it reduce your costperton through intelligent design and robust components? The following overview details a purposeengineered solution for these operational realities.

2. PRODUCT OVERVIEW

This proposal outlines a stationary 250300 tons per hour (tph) hard rock crushing and screening plant. It is designed for highvolume production of highquality aggregates for applications in road base, readymix concrete, asphalt, and railway ballast.

Operational Workflow:
1. Primary Crushing: Dump feed (0750mm) is delivered into a heavyduty vibrating grizzly feeder which bypasses sub150mm fines and directs oversize material to a robust primary jaw crusher.
2. Secondary & Tertiary Crushing: Primary crushed material is conveyed to a secondary cone crusher for reduction. A closedcircuit setup with a large screening unit then routes oversized material to a tertiary cone crusher for final shaping and size refinement.
3. Screening & Stockpiling: Correctly sized material from each stage is screened into precise product fractions (e.g., 05mm, 510mm, 1020mm, 2031.5mm) via multideck vibrating screens and conveyed to designated stockpiles.

Application Scope: Ideal for processing granite, basalt, river pebbles, and other abrasives with compressive strength up to 350 MPa. Suitable for permanent quarry sites or longterm project installations.

Limitations: Not designed as mobile or semimobile plant; requires stable foundation and grid power connection. Maximum feed size is constrained by primary crusher inlet dimensions.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Stepped grizzly bars with adjustable spacing | Operational Benefit: Scalps natural fines at the front end, reduces primary crusher load and wear by up to 15% | ROI Impact: Lowers energy consumption in primary stage and extends jaw plate life

HighEfficiency Hydraulic Cone Crushers | Technical Basis: Hydroset system for CSS adjustment under load & automatic overload protection | Operational Benefit: Enables realtime adjustment for product consistency and protects the machine from tramp metal damage without stopping production | ROI Impact: Minimizes unplanned downtime events; improves yield of inspec product by an estimated 812%

Centralized PLC Control System | Technical Basis: Programmable Logic Controller with touchscreen HMI monitoring motor loads, bearing temperatures, and bin levels | Operational Benefit: Allows singleoperator oversight of the entire flow, provides early fault diagnostics | ROI Impact: Reduces operational staffing requirements; predictive alerts prevent catastrophic component failure

Reinforced Belt Conveyor System | Technical Basis: DIN/ISO standard idlers with sealed bearings; impact beds at loading points | Operational Benefit: Significantly reduces belt wear from material abrasion and minimizes spillage | ROI Impact: Extends belt service life by approximately 30%, lowering longterm conveyor maintenance costs

MultiDeck HighFrequency Screens | Technical Basis: Independent dualvibrator mechanism with adjustable stroke/ frequency| Operational Benefit: Maintains high screening efficiency even with damp or fine materials, ensuring strict product gradation control | ROI Impact: Increases saleable product yield by reducing undersize contamination in larger fractions

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This Custom Solution (250300tph Plant) | Advantage (% Improvement) |
| : | : | : | : |
| Tonnage Consistency| +/ 15% fluctuation with variable feed hardness| +/ 7% fluctuation due to advanced chamber optimization & feeder control| ~53% more consistent output |
| Liner Wear Life (Secondary)| Manganese liners lasting ~120k tons| Specified highchrome martensitic liners lasting ~180k tons| ~50% extended service life |
| Power Consumption per Ton| Estimated average of 1.8 2.0 kWh/t| Optimized circuit design averages 1.6 1.75 kWh/t| ~10% reduction in energy cost |
| Setup & Commissioning Time| Typically 1014 days postcomponent delivery| Preassembled modules reduce onsite work to ~7 days| ~30% faster timetoproduction |

5. TECHNICAL SPECIFICATIONS

Designed Capacity: Guaranteed throughput of hard rock (160 MPa compressive strength): 280 tph. Maximum achievable throughput under optimal conditions: 320 tph.
Power Requirements: Total installed power approximately 650 kW. Primary voltage requirement: 400V/50Hz or customized.
Key Material Specifications: Primary crusher jaw plates are ASMT A128 manganese steel; Cone crusher mantles/concaves are highchrome alloy; Screen meshes are polyurethane or tensioned wire cloth.
Major Equipment Dimensions (LxWxH):
Primary Jaw Crusher Module: ~9m x 4m x 4m
Screening & Tertiary Module: ~12m x 6m x 5m
Control Cabin: Standard ISO container dimensions.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication systems.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: An existing quarry needed to expand output from 150tph to meet new contract demands but had limited space for plant footprint expansion.
Solution: Implementation of this compact yet highyield custom crushing plant featuring threestage crushing within two main modules.
Results: Achieved sustained output of 290tph within the existing allocated area; improved product cubicity raised the premium aggregate yield by 11%, directly increasing revenue per ton shipped.

Road Construction Material Supply

Challenge: A contractor required consistent supply of multiple certified aggregates (base course, subbase) from highly variable river gravel feed for a major highway project.
Solution: Deployment of this plant configured with precise screening decks and tertiary shaping crushers.
Results: Plant reliably produced over 270tph across four specification grades simultaneously; gradation compliance exceeded 98%, eliminating material rejection delays at the construction site.

7. COMMERCIAL CONSIDERATIONS

Our commercial offering is structured around providing predictable total cost of ownership:

Equipment Pricing Tiers: We offer three core configurations:
Tier A (Essential): Includes core crushing/screening units with standard electrical controls.
Tier B (Recommended): Adds PLC automation system dust suppression kit modular walkways/service platforms.
Tier C (Premium): Incorporates full environmental enclosures advanced vibration monitoring on all major drives automated lubrication system.

Optional Features / Upgrades: Highfrequency washing screen attachment metal detector/magnetic separator hybrid diesel/electric power module extended conveyor systems.

Service Packages: Choose from annual inspection plans comprehensive wear parts contracts (12/24 months) remote technical support packages.

Financing Options: We collaborate with industrial financing partners to offer leasetoown structures operating leases or traditional equipment loans tailored to project cash flow models.

8.FAQ

1.Q What level of site preparation is required before installation?
A The plant requires stable concrete foundations designed per supplied load drawings typically requiring two weeks of civil works prior to equipment arrival depending on site conditions.

2.Q How does this plant handle wet or sticky feed material?
A The configuration includes specific screen deck recommendations such as polyurethane panels mesh heating systems optional air blowers which can be specified based on your expected material moisture content preventing blinding issues common in standard designs.

3.Q What is the expected operational manpower requirement?
A Field data shows that with the centralized PLC control system one trained operator can manage the entire crushing circuit from the control cabin supplemented by one ground assistant for routine visual inspections stockpile management reducing direct labor costs versus manual plants.

4.Q Are spare parts readily available?
A We maintain regional inventory hubs for all critical wear parts such as crusher liners screen meshes conveyor idlers Standard lead times for nonstock items are documented transparently within our service agreement ensuring minimal disruption availability guarantees can be negotiated

5.Q Can we later add equipment like a VSI crusher for manufactured sand production?
A Yes The plant layout electrical infrastructure are designed with future expansion capacity Integration points ducting provisions allow addition vertical shaft impact VSI crusher sand washing unit without major structural modifications protecting your initial investment