H1: ODM Stationary Crushing & Planta de cribado: Engineered for Maximum Uptime and Tonnage

1. Addressing Your Core Operational Challenges in Aggregate Production

Managing a fixed crushing site presents distinct, desafíos costosos. Downtime isn't just lost production; it's missed contracts and eroding margins. ¿Estás enfrentando:
Paros no planificados: Fallas de rodamientos, bloqueos de la trituradora, and conveyor issues can halt your entire line. Every hour of downtime can cost thousands in lost revenue and idle labor.
Producto final inconsistente: Fluctuations in feed material or improper calibration lead to offspec aggregate, resultando en el rechazo del producto, costos de retrituración, y relaciones dañadas con los clientes.
Alta complejidad de mantenimiento: Disjointed equipment from multiple suppliers creates a spare parts nightmare and extends maintenance windows, straining your operational budget.
Flujo de materiales ineficiente: Bottlenecks between crushing stages or screening units cap your plant's true capacity, forcing you to run longer hours at higher cost per ton.
Costos operativos crecientes: Accionamientos energéticamente ineficientes, consumo excesivo de piezas de desgaste, and high manual labor for monitoring directly reduce your profitability per cubic meter.

The question is not just how to crush rock, but how to build a reliable, predictable production asset. The solution lies in a fully integrated system designed from the ground up for synchronized performance.

2. Descripción general del producto: The Integrated Stationary Crushing & Planta de cribado

The ODM Stationary Crushing & Screening Plant is a complete, hardwired processing circuit engineered for highvolume aggregate production in quarrying and mining applications. It transforms raw feed (0800milímetros) into precisely graded final products (p.ej., 05mm arena, 520mm agregado).

Flujo de trabajo operativo:
1. Alimentación primaria & Aplastante: Dump trucks feed a vibrating grizzly feeder which removes fines and directs oversize to a robust primary jaw crusher for initial size reduction.
2. Intermediate Processing & Cribado: Crushed material is conveyed to a secondary cone crusher for further reduction. Output is then routed to a multideck vibrating screen for classification.
3. Clasificación de productos & Almacenamiento: Onspec material from each screen deck is conveyed to designated stockpiles. Oversize is recirculated back to the appropriate crusher in a closedcircuit loop.

Ámbito de aplicación: Ideal for hightonnage production of aggregates for concrete, asfalto, and road base. Adecuado para procesar granito, basalto, caliza, and other abrasive ores.

Limitaciones: This is a fixedinstallation solution requiring foundational concrete works and grid power connection. No está diseñado para reubicaciones frecuentes..

3. Características principales: Engineering Meets Operational ROI

Marco estructural modular | Base técnica: Prefabricado, hightensile steel sections with machined connection points | Beneficio operativo: Permite más rápido, more precise onsite installation with reduced crane time and foundation work | Impacto del retorno de la inversión: Cuts installation timeline by up to 30%, reducing timetorevenue.

Sistema de control PLC centralizado | Base técnica: Controlador lógico programable con interfaz hombre-máquina (HMI) panel | Beneficio operativo: Allows singleoperator monitoring and control of the entire flow from feeder to final conveyor; proporciona alertas de diagnóstico | Impacto del retorno de la inversión: Reduces labor requirements by approximately 1 FTE per shift while improving response time to anomalies.

HeavyDuty Vibrating Screen with QuickDeck Change | Base técnica: Rubbermounted screen box with tensioned wedgewire or polyurethane panels | Beneficio operativo: Minimizes vibration transfer to structure; allows screen media replacement in hours vs. días | Impacto del retorno de la inversión: Increases annual availability by ~2% and reduces maintenance labor costs.

Crusher Cavity Optimization | Base técnica: Computeraided design of crushing chamber geometry matched to expected feed material | Beneficio operativo: Maximizes reduction ratio per pass, improves product shape (Cubicidad), and promotes even wear liner utilization | Impacto del retorno de la inversión: Boosts throughput by 515% while extending wear part life cycles.

Supresión de polvo & Sistema de contención | Base técnica: Strategically placed spray nozzles at transfer points with encapsulation skirts | Beneficio operativo: Mantiene el cumplimiento normativo para las emisiones de partículas.; protects bearings and motors from dust ingress | Impacto del retorno de la inversión: Avoids regulatory fines and reduces premature bearing failures by an estimated 40%.

Layered Walkways & Plataformas de mantenimiento | Base técnica: Full perimeter access with safety handrails integrated into the plant design | Beneficio operativo: Enables safe visual inspections, routine greasing, and component servicing without specialized scaffolding | Impacto del retorno de la inversión: Promotes proactive maintenance culture; reduces risk of safety incidents and associated downtime/costs.

4. Ventajas competitivas: Ganancias de rendimiento cuantificables

| Métrica de rendimiento | Punto de referencia estándar de la industria | ODM Stationary Plant Solution | Ventaja documentada |
| : | : | : | : |
| Disponibilidad de planta (Tiempo de ejecución programado) | 9092% | 9496%| +4% Mejora |
| Consumo de energía por tonelada procesada| Varía según el tipo de roca.| Optimized motor loads & unidades eficientes| Arriba a 12% Reducción |
| Costo de piezas de desgaste por tonelada métrica| $0.85 $1.10 Dólar estadounidense| Matched chamber design & selección de aleaciones| 1520% Reducción |
| Instalación & Tiempo de puesta en servicio| 810 Semanas (from foundation)| Modular frame & unidades preensambladas| ~30% Faster (67 Semanas)|
| Required Operating Labor per Shift| 34 Personnel| Centralized PLC control system| Reducido por 1 Operator |

5. Especificaciones técnicas

Rango de capacidad de diseño: 200 800 TPH (configurable based on model).
Requisito de energía primaria: 400V/50Hz o 480V/60Hz; Potencia Total Instalada: 350kW 800kW.
Especificaciones clave de materiales:
Revestimientos de trituradora: Acero al manganeso (14%,18%,22%) or Chrome Iron Alloy options.
Cubiertas de pantalla:Tensioned Polyurethane or HighCarbon Steel Wire Mesh.
Cinta transportadora:Synthetic Fabric Ply (EP630/3) with minimum 12mm top cover.
Acero estructural:S355JR grade with hotdip galvanized finish on walkways.
Typical Physical Footprint (for a 350TPH plant): ~35 millones (l) x 22m (W.) x 15m (h).
Rango de operación ambiental: Temperatura ambiente 20°C a +45°C; niveles de emisión de polvo que cumplen con <10mg/Nm³ standards when used with suppression system.

6. Escenarios de aplicación

Proyecto de Ampliación de Cantera de Granito

Desafío:A quarry needed to increase output by over 60% but had limited space for plant expansion within their existing lease boundary.Solution:Un compacto,OEMdesigned threestage crushing circuit was installed,fitting into the footprint of an older twostage plant.The design included a large primary jaw crusher followed by two secondary cone crushers in parallel configuration feeding shared screens.This allowed higher throughput without increasing land use.The centralized control system was integrated into their existing site office via fiber optic cable.The new layout reduced internal haulage distances significantly.Retrofitted spray systems kept dust under control during blasting operations near residential areas.Finally,the modular construction allowed commissioning during planned seasonal shutdown minimizing disruption.Financing was secured through an equipment lease agreement preserving capital for other site improvements.Regular service visits ensured optimal performance throughout the warranty period leading them purchase an extended coverage plan.This holistic approach transformed their operational constraints into competitive advantage securing several large infrastructure contracts previously out reach due capacity limitations

Procesamiento de piedra caliza para alimentación de plantas de cemento

Desafío:A cement producer required consistent 25mm feed for their raw mill,but variations in quarry moisture content caused frequent clogging in their existing impact crusher.Solution:The implementation featured a primary jaw crusher followed by a heavyduty cone crusher equipped with automated setting regulation.Air cannons were installed at key hopper points,and conveyor skirts were extended.The PLC system was programmed to adjust feeder speed based on crusher motor load.Field data after six months showed clogging events reduced by over95%.Product consistency improved dramatically meeting the 25mm spec99.%of the time.This reliability allowed the cement kiln department optimize their own processes knowing raw material supply would be uninterrupted

Proyecto de Infraestructura Urbana Reciclaje

Desafío:A major road construction project mandated onsite recycling of demolished concrete to reduce truck traffic environmental impact but faced strict noise dust regulations tight urban site.Solution:A semimobile configuration was deployed featuring extensive acoustic enclosures around all major noise sources like crushers screens fully enclosed conveyors waterbased dust suppression systems every transfer point.The plant processed over500000tons recycled concrete aggregate meeting all stringent local environmental standards avoiding thousands truck movements city center

Consideraciones comerciales

Pricing is structured around plant capacity,nivel de personalización,and chosen component brands(e.g.,crusher motor manufacturer).We offer three primary tiers:

1.Basic Configuration Tier:Covers core functionality standard components proven reliability suitable budgetconscious operations seeking essential performance.Pricing typically ranges from$750000to$1million USD depending capacity

2.Nivel de rendimiento(Recomendado):Includes features like centralized PLC automation premium wear liners enhanced dust suppression walkways platforms.Pricing typically ranges from$ million$ million USD

3.Nivel Premium llave en mano:Fully customized solution including advanced predictive monitoring sensors extended warranty comprehensive operator training package civil engineering drawings support.Pricing determined specific project scope

Actualizaciones de características opcionales:
Advanced vibration monitoring sensors critical bearings
Sistemas de lubricación automatizados
Overband magnetic separator ferrous metal removal
Additional finished product conveyor stackers
Kit de inicio de repuestos

Paquetes de soporte de servicio:
Standard Warranty months parts labor excluding wear items
Extended Coverage Plans years available purchase
Annual Maintenance Contracts include scheduled inspections priority technical support discounted spare parts
OnDemand Field Service Technician dispatch available global network partners

Opciones de financiación:
We work accredited financial partners offer:
Equipment leasing structures preserve working capital
Term loans competitive rates project financing
RentaltoOwn programs lower initial commitment

Sección de preguntas frecuentes

¿Qué pasa si la dureza del material de alimentación cambia con frecuencia??
Our cone crushers recommended Performance Tier feature hydraulic adjustment CSS clearing allow quick adaptation different rock characteristics without stopping process ensuring consistent output quality varying conditions

How does this integrate existing equipment like my primary excavator loaders?
Plants designed flexible feeding arrangements accommodate different loading methods We provide interface specifications hopper heights capacities ensure compatibility your current loading fleet minimizing integration issues

¿Cuál es el plazo típico de entrega??
For standard configurations lead time typically weeks exworks following deposit receipt Site commissioning supervised our engineers requires approximately weeks depending complexity local readiness

¿Hay piezas de repuesto disponibles en todo el mundo??
Yes maintain strategic inventory critical components partner global logistics providers ensure expedited shipping Additionally provide detailed part numbers crossreferences equivalent items facilitate local sourcing noncritical parts where appropriate

¿Ofrecen capacitación para operadores??
Yes comprehensive training included Turnkey Tier optional others covers normal operation routine maintenance troubleshooting safety procedures Training conducted both our facility yours ensure competence confidence your team