1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are you managing a stone quarry operation where inconsistent feed, tiempo de inactividad no planificado, and rising operational costs are eroding your margins? Key challenges in primary crushing include:

Tiempo de inactividad excesivo para mantenimiento: Frequent liner changes and unexpected component failures in the primary crusher can halt your entire processing line for hours, costing thousands in lost production per event.
Altos costos de piezas de desgaste: Abrasive feed material leads to rapid wear of crusher jaws, mantos, y cóncavos, creating a significant and recurring expense for your parts inventory.
Rendimiento inconsistente & Gradación del producto: Fluctuations in feed size or hardness can cause chokefeeding or poor cavity utilization, resulting in suboptimal tonnage and offspec product that requires recrushing.
Ineficiencia energética: Older or poorly configured crushing plants consume excessive power per ton of processed material, impactando directamente sus resultados a medida que aumentan los costos de energía.
Preocupaciones por la integridad estructural: The immense forces generated in a primary crushing station demand a fabricated structure of exceptional durability. Inadequate design can lead to costly frame fatigue, cracks, and alignment issues over time.

How do you select a crushing plant fabricator that not only provides robust equipment but also delivers the operational reliability and total cost of ownership metrics that your business requires?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: ISOCertified Stationary Primary Crushing Plant

We engineer and fabricate heavyduty, stationary primary crushing plants designed as the cornerstone of hard rock quarry operations. These turnkey solutions are built to receive blasted feed from haul trucks and reduce it to a consistent, producto transportable para procesamiento secundario.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: runofquarry (ROQ) material is dumped into a rugged vibrating grizzly feeder (VGF VGF), which scalps out fine undersize material to bypass the crusher, mejorando la eficiencia.
2. Reducción de tamaño primario: Oversize material is directed into a highcapacity jaw crusher (o trituradora giratoria, depending on application) donde se comprime y fractura contra superficies fijas y móviles.
3. Transporte del producto: Crushed material is discharged onto a heavyduty main product conveyor, transporting it to the next stage of the processing circuit.

Ámbito de aplicación: Ideal para procesamiento de granito de alto tonelaje, basalto, caliza, y otros agregados abrasivos. Suited for permanent installation in largescale quarry operations.

Limitaciones: No diseñado para aplicaciones portátiles o móviles. Maximum feed size is determined by crusher model selection; extremely sticky or claybound materials may require additional preprocessing.

3. CARACTERÍSTICAS PRINCIPALES

Modular Fabricated Base Frame | Base técnica: CAD optimizado, highstrength steel weldment with internal reinforcing diaphragms | Beneficio operativo: Provides an unwavering foundation that maintains precise crusher and motor alignment under cyclical loading | Impacto del retorno de la inversión: Eliminates costly realignment downtime and extends bearing & drive component life by up to 30%.
Integrated Maintenance Platforms & Acceso | Base técnica: Ergonomic design per ISO safety standards with nonslip grating, guardrails, and strategic service points | Beneficio operativo: Your crew can perform routine inspections, liner checks, and maintenance tasks safely and efficiently | Impacto del retorno de la inversión: Reduces service time by an average of 25%, Reducir los costos laborales y aumentar la disponibilidad de la planta..
Alimentador Grizzly Vibrante de Servicio Pesado (VGF VGF) Section | Base técnica: Robust deck construction with replaceable grizzly bars and highinertia vibrator motors | Beneficio operativo: Effectively removes fines while absorbing direct impact from haul truck dumping | Impacto del retorno de la inversión: Increases primary crusher capacity by preventing chokefeeding with fines; protege la trituradora de cargas de impacto.
Lubricante centralizado & Sistema hidráulico | Base técnica: Manifolded system with failsafe indicators and easyaccess service ports | Beneficio operativo: Permite seguridad, limpio, and consistent lubrication of all critical crusher bearings from a single location | Impacto del retorno de la inversión: Standardizes maintenance procedures prevents lubrication failures which are a leading cause of major component damage.
Cable Management & Utility Routing | Base técnica: Prefabricated steel conduits and trays integrated into the plant structure | Beneficio operativo: Protects power and control cables from damage dust contamination ensuring reliable electrical supply | Impacto del retorno de la inversión: Minimizes electrical faults reduces installation time onsite by providing a plugandplay wiring infrastructure.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Práctica estándar de la industria | Our ISOCertified Crushing Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Structural Durability (Fatigue Life) | Fieldwelded fabrication with variable quality control; potential for stress points. | Plantwide FEA analysis; precision shopwelding under controlled conditions per ISO 38342. +40% estimated service life before major refurbishment. |
| Instalación en sitio & Tiempo de puesta en servicio| 46 weeks for foundation work assembly alignment testing. Modular design with preassembled sections; laseraligned at factory. 50% onsite labor time reduced project risk. |
| Disponibilidad operativa (tiempo de actividad) ~92% based on typical maintenance schedules unplanned stops.| >95% documented via telemetry from installed units optimized access predictive maintenance design.| +3 percentage points translating to significant annual tonnage gains. |
| Consumo de energía por tonelada procesada| Varies widely older drives directonline starting.| Engineered drive train efficiency softstart systems optimized kinematics.| Los datos de campo muestran 815% reducción del consumo energético específico |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable for throughputs from 400 a 2 000+ toneladas métricas por hora (TPH)
Opciones de trituradora primaria: Cursor de mandíbula (900 x 1200 mm a 1500 x 2000mm) o trituradora giratoria primaria
Grizzly Feeder: Anchos desde 1 200mm a 2 400milímetros; longitudes desde 4 500mm a 7 500milímetros
Requisitos de energía: Potencia total instalada normalmente entre 250 kilovatios 600 kW dependiendo de la configuración
Especificaciones de materiales: Main frame fabricated from S355JR structural steel; wear surfaces utilize AR400 abrasionresistant steel liners
Dimensiones físicas (Típico): Huella aproximada de 18m (l) x8m (W.) x 9m (h). Custom designs available
Environmental Operating Range Designed for ambient temperatures from 20°C to +45°C dust moisture conditions typical of outdoor quarry operation

6. ESCENARIOS DE APLICACIÓN

Granite Quarry Expansion Southeast Asia Challenge A major quarry needed to double primary circuit capacity but had limited space for new foundations faced stringent noise/vibration regulations Solution A compact highcapacity jaw crusher plant was designed with an integrated acoustic enclosure vibrationisolation pads mounted on a single deeppile foundation Results Achieved target throughput of 1 200 TPH within existing site footprint community noise complaints reduced by 60%

Basalt Processing Plant Upgrade North America Challenge Chronic downtime due to frame fatigue cracks poor accessibility for mantle changes on an aging primary station Solution Complete replacement with a customfabricated primary plant featuring reinforced modular base walkin maintenance platforms around the crusher Results Mantle changeout time reduced from 36 horas para 14 hours no structural integrity issues reported after 3 years of continuous operation

7 CONSIDERACIONES COMERCIALES

Our ISOcertified fabrication process ensures transparent costing predictable delivery schedules

Niveles de precios
1 Base Plant Includes fabricated structure VGF crusher mounting main discharge conveyor walkways ladders
2 Premium Package Adds centralized automated lube system integrated dust suppression spray system premium motor starters
3 Turnkey Pro Includes full electrical control package PLC instrumentation advanced condition monitoring sensors

Optional Features Acoustic cladding special coatings for corrosive environments custom feed hopper designs belt scales metal detection

Service Packages Extended warranty plans scheduled inspection services remote performance monitoring subscriptions wear part supply agreements

Financing Options Available through partner institutions including equipment leasing longterm rental plans tradein options for existing assets

8 Preguntas frecuentes

¿Qué nivel de preparación del sitio se requiere antes de la entrega??
We provide detailed foundation drawings load data anchor bolt templates Your contractor prepares the civil works according to our specifications ensuring our team can commence efficient mechanical erection

How does your fabrication quality control impact longterm reliability?
Our ISO 9001 38342 certifications mandate documented procedures for material traceability welding qualifications dimensional checks This systematic approach eliminates defects that cause premature failure ensuring predictable lifecycle costs

Can this plant be integrated with my existing secondary circuit conveyor?
Yes Our design team will engineer the discharge height conveyor speed transfer point to match your existing system specifications We ensure seamless material flow integration

¿Cuál es el plazo de entrega típico desde la realización del pedido hasta la puesta en servicio??
Lead times vary based on project scope complexity A standard configured plant typically has a 68 month timeline including engineering procurement fabrication testing disassembly shipping Site commissioning requires approximately 34 weeks with our supervision

Do you provide operational training for our crew?
Yes Comprehensive training covering safe operation routine maintenance procedures basic troubleshooting is provided during commissioning Documentation includes detailed operation maintenance manuals