H1: Maximize Throughput and Minimize Cost with Custom Crushing and Screening Equipment

PAINPOINT DRIVEN OPENING

Are unpredictable feed materials and fluctuating market demands eroding your profit margins? Inconsistent product specification, excessive wear part consumption, and unplanned downtime are not just operational headaches—they directly impact your bottom line. Consider these common challenges:
Variable Feedstock: Hardness, abrasiveness, and moisture content fluctuate, causing chokeups, accelerated wear, and offspec product.
Unscheduled Downtime: Component failures during critical production windows lead to costly standstills for repairs and lost contract opportunities.
Inefficient Material Flow: Bottlenecks between crushing stages or screening decks limit overall plant capacity, leaving potential revenue untapped.
High Operational Costs: Frequent liner changes, high energy consumption per ton processed, and manual adjustments consume labor and budget.

Is your operation sacrificing efficiency by forcing nonuniform material through a generic system? A tailored approach to material reduction can address these exact issues.

PRODUCT OVERVIEW: CUSTOM CRUSHING AND SCREENING SOLUTIONS

A custom crushing and screening plant is an engineered system designed from component selection to layout for your specific feed material, target product specifications, site constraints, and production goals. Unlike standard units, it optimizes the entire workflow:
1. Primary Size Reduction: Customconfigured jaw or gyratory crushers selected for maximum intake size and hardness.
2. PreScreening & Scalping: Efficient removal of fines or oversize material before secondary crushing to reduce unnecessary load and wear.
3. Secondary/Tertiary Crushing: Cone or impact crushers chosen and set for the required reduction ratio and product shape (cubicity).
4. Precise Product Classification: Multideck vibrating screens sized and angled to accurately separate multiple product fractions.
5. Integrated Material Handling: Customlength conveyors, transfer points, and chute work designed to eliminate plugging and spillage.

Application Scope & Limitations: Ideal for fixedsite quarries, largescale mining operations, major construction projects requiring onsite aggregate production, and advanced recycling facilities processing complex feed streams. A custom solution requires a detailed material analysis and site assessment; it is not typically suited for operations requiring frequent relocation.

CORE FEATURES

Engineered Chamber Geometry | Technical Basis: Kinematic dynamics & material trajectory modeling | Operational Benefit: Optimized nip angle and crushing stroke for your specific material increases throughput by 1525% while producing a more consistent particle size distribution. | ROI Impact: Higher yield of inspec product reduces recirculating load & energy cost per ton.

ApplicationSpecific Wear Packages | Technical Basis: Metallurgical analysis of abrasion/impact forces | Operational Benefit: Liners, mantles, and screen media alloys are selected based on your material's silica content & impact index, extending service life by 3050%. | ROI Impact: Lower cost per ton for wear parts & reduced frequency of changeout downtime.

Dynamic Load Management System | Technical Basis: Realtime amperage & pressure monitoring with automated control logic | Operational Benefit: Crusher setting & feeder rate automatically adjust to prevent overloads in iron or tramp metal events, protecting the drive train. | ROI Impact: Avoidance of catastrophic component failure saves an average of $50k+ per incident in parts/labor.

Modular Plant Configuration | Technical Basis: Structural engineering with standardized interface points | Operational Benefit: Enables future expansion (adding a tertiary circuit) or reconfiguration for new products without complete rebuilds. | ROI Impact: Protects capital investment longterm; adapts to new contract requirements with minimal additional expenditure.

Centralized Greasing & Condition Monitoring | Technical Basis: Automated lubrication intervals based on bearing load cycles & integrated vibration sensors | Operational Benefit: Ensures critical bearings receive correct lubrication without manual intervention; provides early warning of misalignment or component degradation. | ROI Impact: Increases mean time between failures (MTBF) by up to 40%, enabling planned maintenance.

COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Plant) | Custom Crushing And Screening Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Equipment Effectiveness (OEE) | 7075% typical availability/utilization/quality rate mix| 8590% through optimized flow & reliability features| +1520% |
| Tons Processed per Wear Part Dollar| Baseline (varies by material) | Increased via alloy selection & chamber design optimization| +3050% |
| Energy Consumption (kWh/ton) | Dependent on poorly matched motor sizing & recirculating loads| Reduced via efficient load distribution & minimized bottlenecks| 1020% |
| Product Specification Consistency (% within tolerance) | Reliant on operator adjustment; can vary ±10%| Automated settings & matched components maintain ±5% tolerance| +50% improvement in consistency |

TECHNICAL SPECIFICATIONS

Specifications are determined by client requirements; below is a representative model framework:

Design Capacity Range: 200 1,500 tonnes per hour
Primary Crusher Options: Jaw Crusher (1,200mm x 830mm feed opening) or Gyratory Crusher (54” head diameter), selected based on feed size analysis.
Secondary/Tertiary Crusher Options: Heavyduty cone crushers with multiple crushing chamber profiles available; hydraulic adjustment & clearing systems standard.
Screening Decks: Highenergy vibrating screens up to 3 decks; sizes from 2.4m x 6m to 3m x 8m; polyurethane or wire mesh panels as required.
Power Requirements: Integrated electrical package from 800 kVA to 2500 kVA depending on configuration; all motors premium efficiency IE3/IE4 class.
Structural Fabrication: Primary frame constructed from hightensile steel (ASTM A572 Grade 50); abrasionresistant steel liners (AR400/500) at all wear points.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dust suppression system manifold included as standard; sound enclosures available to achieve <85 dB(A) at operator stations.

APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: An existing quarry needed to increase production of railway ballast (40mm +20mm chip) while simultaneously producing more manufactured sand (5mm). Their existing plant created excessive fines in the ballast fraction.
Solution: Implementation of a custom threestage plant featuring a primary jaw crusher, secondary cone crusher in closed circuit with a doubledeck screen for ballast separation, and a tertiary cone crusher dedicated to sand production with an integrated air classifier.
Results: Ballast yield increased by 22%, meeting stringent fracture count specifications. Sand production provided a new highvalue product line. Overall plant throughput rose by 35%.

C&D Recycling Facility Upgrade

Challenge: A recycling operation faced constant jamming in secondary impactors due to uncrushable contaminants (rebar, wood) in concrete feed. Downtime was exceeding 15 hours weekly.
Solution: A customdesigned heavyduty scalping screen was installed ahead of secondary crushing to remove 40mm fines and oversize contaminants via dualmaterial separation decks. The downstream impactor was specified with enhanced tramp metal protection.
Results: Unplanned downtime related to jams decreased by over 90%. The removal of fines prior to secondary crushing reduced wear rates by an estimated 28%. Plant availability increased significantly.

COMMERCIAL CONSIDERATIONS

Custom solutions are priced based on scope. We provide transparent tiered engineering proposals:

1. Base Equipment Package: Includes primary crusher feeder module(s), one secondary crushing/screening module configured per initial analysis,
conveyors,and walkway access structures.Estimated Range:$2M $5M USD
2. Optional Features:
Tertiary Crushing/Specialized Fines Recovery Module
Full PLC Automation & SCADA Control Room
Advanced Dust Suppression Fogging System
OnBoard Weighing & Production Tracking
Extra Set of ApplicationSpecific Wear Parts

3.Service Packages:
Commissioning Supervision& Operator Training
Planned Maintenance Agreements with guaranteed response times
Remote Diagnostics& Predictive Analytics Subscription

4.Financing Options:
Flexible commercial structures are available including capital lease,purchase leaseback,and project financing tailored for major capital equipmentwith terms alignedto expected payback periods

FAQ

Q1.How do you determine the right crusher type(jaw vs.gyratory vs.cone vs impactor )for our custom plant?
A1.The selection is based on laboratory analysisof your representative feed sample measuring compressive strength abrasion index(Al)and moisture content combinedwith your required capacityand product shape goals.Primary stage selection hinges on feed sizeand hardness while secondary/tertiary choices focuson reduction ratioand cubicity

Q2.What is the typical lead timefrom design approvalto commissioningfor acustomcrushingandscreeningplant?
A2.Fora comprehensive system lead timesrange from8to14months.This includesdetailed engineering fabrication assembly factory testing disassemblyfor shipmentand re commissioningat your site Timelinesare confirmedafterthe initial scoping phase

Q3.Can acustomplantbe relocatedif oursite changes?
A3 Yes themodular design philosophyensures key sectionscan be dismantled transportedand re erectedat anew site Structural integrityis maintainedthroughthis process thoughsome reassembly inspectionand recertificationis required whichwe can manageunder aservice contract

Q4 How doesacustomsolutionimpactourpermanencestaffingrequirements?
A4 Field datashows thatwell automatedcustomplants oftenrequire feweroperators formanual monitoringbut place apremiumon higher skilledmaintenance technicians Our trainingprogramsare designedtoupskillyour teamtomanage the moresophisticatedsystems effectively

Q5 Are performance guaranteesofferedwith acustomcrushingandscreeningsolution?
A5 Yes we provideguaranteeson throughputcapacity finalproductgradation meeting agreed specifications powerconsumptionperton processedand keywear partlifebasedon the providedfeedmaterialanalysis Theseare formalizedinthecontract

Q6 What happensif ourfeedmaterialcharacteristicschangesignificantlyovertime(e.g mining adifferentseam)?
A6 The modularnatureallowsfor future reconfiguration Chambersettingswear linerprofilesandevencrusherchambercomponentscan be changedorupdatedto accommodate newmaterialpropertieswithin theexistingplantfootprint This adaptabilityis acorebenefitofcustomengineering

Q7 Howisthepricingstructuredandwhatdepositsarerequired?
A7 Pricingisfixeduponfinalengineeringapproval Apayment scheduleistypically alignedwithmajor manufacturingmilestones suchasreleaseofengineering steelcutting majorassembly completion factoryacceptancetestingand shipment Initialdepositrequirementsvarybasedonprojectsizeandfinancingmethod