1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando los márgenes de su proyecto?? Para gerentes de planta y contratistas, the crushing and screening circuit is often the bottleneck where profit is won or lost. Los desafíos comunes incluyen:
Tiempo de inactividad no programado: Component failures in critical crushers or screeners halt entire production lines, costando miles de dólares por hora en producción y mano de obra perdidas.
Altos costos de mantenimiento: Frequent wear part replacement and extensive manual adjustments consume both budget and skilled technician hours.
Calidad del producto inconsistente: Inefficient screening and improper crushing lead to offspec aggregate, resultando en el rechazo del producto, costos de reprocesamiento, y relaciones dañadas con los clientes.
Ineficiencia energética: Más viejo, nonoptimized equipment consumes excessive power per ton of material processed, impactando directamente su resultado final.
Configuración rígida: Fixed plants cannot adapt to changing feed material or final product requirements, limiting operational flexibility and contract opportunities.

What if your primary crushing station and screening deck could deliver not just throughput, pero rendimiento predecible, menor costo por tonelada, and the agility to meet shifting market demands?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This product line encompasses a range of premium stationary and semistationary crushing and screening plants engineered for highvolume aggregate production, pretrituración minera, y construcción & reciclaje de demolición. El flujo de trabajo operativo está diseñado para un funcionamiento continuo., efficient material processing:

1. Alimentación primaria & Aplastante: Dump trucks feed material into a rugged vibrating grizzly feeder which removes fines and directs oversize to a highcapacity jaw or gyratory crusher for initial size reduction.
2. Intermediate Conveying & Aplastante: Crushed material is conveyed to secondary cone or impact crushers for further refinement, with metal detectors and tramp iron relief systems protecting downstream components.
3. Pre-selección & Clasificación: Material may be routed through a scalping screen before secondary crushing to improve efficiency.
4. Proyección final & Almacenamiento: The crushed aggregate is classified into precise specifications by multideck vibrating screens, with conveyors directing sorted material to designated stockpiles.

Ámbito de aplicación: Ideal para canteras a gran escala, hard rock mining primary circuits, y grandes proyectos de infraestructura que requieren, agregados de alta calidad (040mm+). Limitations include suitability primarily for fixed or semifixed installation sites; highly mobile contract crushing requires dedicated portable equipment.

3. CARACTERÍSTICAS PRINCIPALES

Ajuste de CSS de Hydroset | Base técnica: Pistón hidráulico que soporta el eje principal. | Beneficio operativo: Ambiente cerrado (CSS) can be adjusted safely in under 60 segundos sin parar la trituradora, enabling rapid response to product gradation changes. | Impacto del retorno de la inversión: Eliminates hours of manual shim adjustment downtime per change, increasing plant utilization by up to 7% anualmente.

Sistema de medios de pantalla modular | Base técnica: Interlocking polyurethane or rubber panels with tensioning rails | Beneficio operativo: Panels can be replaced by a twoperson crew in under 30 minutes per deck without specialized tools. | Impacto del retorno de la inversión: Reduces screen deck maintenance downtime by over 50% compared to traditional woven wire cloth systems.

Automatización de plantas basada en PLC | Base técnica: Controlador lógico programable centralizado con HMI con pantalla táctil | Beneficio operativo: Monitoriza el consumo de amperios, temperaturas de los rodamientos, y tasas de alimentación; automatically regulates feeder speed and triggers alarms for preventative intervention. | Impacto del retorno de la inversión: Previene fallas catastróficas; Los datos de campo muestran un típico 1520% reduction in unplanned stoppages.

Tecnología de trituradora de accionamiento directo | Base técnica: Crusher coupled directly to motor via Vbelts without gearboxes | Beneficio operativo: Mayor eficiencia de transmisión de energía (encima 95%) and reduced mechanical complexity. | Impacto del retorno de la inversión: Lowers energy consumption by up to 10% versus indirect drives and reduces potential failure points.

Nivel 4 Final / Integración de la unidad de potencia EU Stage V | Base técnica: Factoryintegrated, emissionscompliant diesel gensets or electric motor drives with soft starters | Beneficio operativo: Provides compliant power flexibility for remote sites or grids with limited capacity; soft starters reduce electrical network stress. | Impacto del retorno de la inversión: Simplifies permitting; reduces peak current demand charges on electric installations.

Reinforced BoxSection Conveyor Frames | Base técnica: Highstrength welded steel construction with internal stiffeners | Beneficio operativo: Withstands continuous heavyimpact loading without frame deflection or misalignment. | Impacto del retorno de la inversión: Extends conveyor belt life by maintaining proper tracking; reduces structural maintenance over the plant's lifetime.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Punto de referencia estándar de la industria | Nuestro aplastamiento & Ventaja documentada de la solución de detección |
| : | : | : |
| Toneladas por Hora (TPH) Disponibilidad | 8588% availability over a quarter >90% availability over a quarter +35% mejora |
| Costo por tonelada (Piezas de desgaste) Dólar estadounidense $0.45 $0.55/ton processed USD $0.38 $0.42/ton processed Up to 20% reducción |
| Consumo de energía (kWh/tonelada) ~0,85 1.1 kWh/ton ~0.75 0.95 kWh/ton Up to 15% mejora |
| Tiempo de cambio de medios de pantalla (per deck) ~90 120 minutos <30 minutes Over 60% más rápido |
| Tiempo de ajuste de CSS (trituradora de cono) ~60 90 minutos <2 minutes Over 95% más rápido |

_Availability defined as (Scheduled Operating Time Unscheduled Downtime) / Scheduled Operating Time._

5.ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 400 TPH por encima 1,500 Salida del producto final TPH.
Opciones de trituradora primaria: trituradoras de quijada (1,200Abertura de alimentación de mm x 830 mm.) o trituradoras giratorias primarias (54" modelo).
Trituradoras secundarias/terciarias: Heavyduty cone crushers with multiple chamber options.
Unidades de cribado: Highenergy tripledeck vibrating screens (up to 8m² screening area per deck).
Requisitos de energía: Full plant electric configuration typically requires a mains supply of 800kVA – 2MVA; integrated diesel genset options available.
Especificaciones clave de materiales: Manganese steel crusher jaws/liners (18% Minnesota); Revestimientos Hardox® en tolvas y tolvas; SKF/FAG class bearings throughout.
Dimensiones físicas (Huella vegetal típica): Approximately L70m x W25m x H15m (varies significantly with configuration).
Rango de operación ambiental: Diseñado para temperaturas ambiente de 25°C a +45°C; dust suppression system compliant with <10mg/m³ normas de emisión.

6. ESCENARIOS DE APLICACIÓN

Proyecto de Ampliación de Cantera de Granito

Reto Se necesita una cantera para aumentar la producción de balasto ferroviario (40mm+20mm) por 40% but faced space constraints preventing simple line duplication.
Solution Implementation of a singletrack mounted primary jaw crushing station feeding a dualprocess circuit with secondary cone crushers dedicated to different final products.
Results Achieved target throughput increase within the existing footprint; automated controls allowed quick switching between ballast production and aggregate chips (20milímetros), improving contract flexibility.

Urbano C&D Recycling Facility Upgrade

Challenge A recycling center processing concrete demolition waste experienced excessive wear from rebar contamination and inconsistent final product due to fluctuating feed composition.
Solution Installation of a heavyduty impact crusher with hydraulic apron adjustment for primary reduction paired with an aggressive doubledeck scalping screen fitted with abrasionresistant media.
Results Tramp metal removal efficiency improved by over 80%; consistent final aggregate quality met strict city specification for road base materials; wear part life increased by an average of 35%.

7. CONSIDERACIONES COMERCIALES

Our luxury crushing equipment is positioned as a capital investment focused on longterm total cost of ownership reduction.

Pricing tiers are structured around core plant configuration:
Tier A Base Stationary Plant includes primary crusher feeder module basic screening tower stockpile conveyors starting at approximately USD $2 millón
Tier B Advanced Automated Plant includes all Tier A features plus secondary/tertiary crushing modules PLC automation system advanced dust suppression
Tier C Custom Turnkey Solution fully engineered sitespecific solution including civil works design installation commissioning training

Optional Features Premium ceramic wear liners for highly abrasive applications remote monitoring telemetry package sound attenuation enclosures

Service Packages Annual Platinum Coverage comprehensive parts labor scheduled inspections Gold Coverage partsonly coverage with discounted labor rates

Financing Options Available through partnered financial institutions including operating leases capital leases longterm rentaltoown structures typically structured over 5year terms

8. Preguntas frecuentes

Q What level of ground preparation is required for installation
A These are substantial permanent structures requiring professional civil engineering foundation design typically involving reinforced concrete piers footings Proper site preparation is critical for longterm alignment stability

Q How does this equipment integrate with our existing conveying system
A Our engineering team can design custom transfer chutes control system interfaces provided we receive detailed drawings of your current conveyor specifications Belt widths speeds heights must be matched

Q What is the expected operational lifespan of the main crusher frame
A With proper maintenance excluding wearable liners the main crusher body frames are designed for a minimum service life exceeding 25 years based on finite element analysis fatigue testing

Q Are operators provided training on the new control system
A Yes comprehensive onsite training for both operators maintenance technicians is included as standard during commissioning covering daily operation troubleshooting basic maintenance procedures

Q Can we source common wear parts like screen cloths locally
A While we recommend genuine parts for optimal performance our modular screen system uses standardized panel sizes that can accommodate certain thirdparty media Basic Vbelts bearings are also industrystandard items