1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors overseeing bulk material processing, inefficient crushing and screening is a primary bottleneck. Common challenges include:
High PerTon Cost: Inefficient flow, excessive recirculation, and frequent component wear directly increase your cost per ton of processed material.
Unscheduled Downtime: Unplanned stops for maintenance, blockages, or mechanical failures disrupt entire production schedules, causing significant revenue loss.
Inconsistent Product Gradation: Offspec material results in product rejection, reprocessing costs, and dissatisfied clients.
Rising Labor & Energy Intensity: Equipment requiring constant monitoring, manual adjustment, or excessive power consumption drives up operational expenditures.
Scalability Limitations: Fixed systems struggle to adapt to changing feed material or required product specifications, limiting contract flexibility.

Is your current setup equipped to maximize throughput while controlling these variables? A strategic investment in modern exportgrade crushing and screening equipment is not merely a capital purchase; it is a direct intervention on your bottom line.

2. PRODUCT OVERVIEW

This product line encompasses heavyduty, containerized crushing and screening plants engineered for highvolume primary, secondary, and tertiary processing of aggregates, ore, and industrial minerals. Designed for export and demanding site conditions, these systems transform raw feed into precisely graded end products.

Operational Workflow:
1. Primary Reduction: Raw feed is introduced to a robust jaw or gyratory crusher for initial size reduction.
2. Primary Screening & Conveying: Crushed material is conveyed to a primary screen deck where subsize product is separated; oversize is routed for further crushing.
3. Secondary/Tertiary Processing: Oversize material is directed to cone or impact crushers for additional reduction in closedcircuit with screening units.
4. Final Product Sorting: Multiple deck screens separate the processed material into 35 specified final product fractions.
5. Stockpiling: Finished products are conveyed to designated stockpiles or loading areas.

Application Scope: Ideal for largescale quarrying, mining preconcentration, major infrastructure projects (road base, rail ballast), and commercial aggregate production.
Key Limitations: Not suitable for ultrafine grinding (sub5mm) without specialized circuits; maximum feed size and hardness are defined by modelspecific engineering limits.

3. CORE FEATURES

Advanced Chamber Geometry | Technical Basis: Optimized nip angle and crushing cavity profile | Operational Benefit: Increases firstpass reduction ratio, minimizing recirculating load and wear on downstream components | ROI Impact: Reduces energy consumption per ton by up to 15% and extends liner life

Centralized Grease Automation | Technical Basis: Programmable, highpressure centralized lubrication system | Operational Benefit: Ensures consistent bearing lubrication under all load conditions without manual intervention | ROI Impact: Lowers bearing failure risk by an estimated 70%, directly preventing costly unscheduled downtime

Hybrid Power Flexibility | Technical Basis: Configurable power train accepting grid connection or onboard dieselgenerator sets | Operational Benefit: Enables rapid deployment to remote sites and provides operational resilience during grid instability | ROI Impact: Eliminates infrastructure delays; field data shows a 40% reduction in site commissioning time

Modular Component Design | Technical Basis: Bolttogether substructures with standardized interfaces | Operational Benefit: Simplifies transport in standard containers and allows for strategic component replacement or future circuit reconfiguration | ROI Impact: Cuts international shipping costs by approximately 25% versus monolithic units

Intelligent Process Control (IPC) System | Technical Basis: PLCbased system with load management and CSS adjustment capabilities | Operational Benefit: Automatically regulates feed rates and crusher settings to maintain optimal throughput and product gradation | ROI Impact: Maintains consistent spec yield (>98%), reducing waste and reprocessing

HeavyDuty Vibrating Screen with Deck Access System | Technical Basis: High Gforce exciters mounted on reinforced decks with walkways | Operational Benefit: Provides efficient material stratification and sizing even with sticky or damp feed; allows safe, quick media changes | ROI Impact: Improves screening efficiency by 20%, boosting overall plant capacity

Integrated Dust Suppression & Noise Abatement | Technical Basis: Spray bar systems at transfer points with acoustic encapsulation panels | Operational Benefit: Meets stringent international environmental compliance standards for particulate matter and noise pollution | ROI Impact: Mitigates project delay risks from regulatory noncompliance and community complaints

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Crushing & Screening Solution | Advantage (% improvement) |
|||||
| Tons per Hour (TPH) / kW | Varies by application | Optimized flow design & drive efficiency | +1015% Energy Efficiency |
| Liner Changeout Time | 812 hours (jaw/cone) | Hydraulic adjustment & assisted tooling |35% Downtime |
| Screening Efficiency ~8590% Patented throw & deck design +1012% Yield |
| Mean Time Between Failures (Critical Bearings) ~1218 months Premium seals & grease automation +50% Service Life |
| OnSite Assembly Duration ~1014 days Preassembled modular skids 40% Commissioning Time |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 300 to 1,200 metric tons per hour (TPH), depending on feed material (bulk density ~1.6 t/m³) and product gradation.
Power Requirements: Primary plant power range from 250 kVA to 800 kVA. Available as 50Hz or 60Hz compliant. Hybrid option includes integrated Stage V/Tier 4 Final diesel generators.
Material Specifications: Highabrasion steel wear plates (HB400+); Crusher mantles/concaves in premium manganese steel (18%22%); Screen decks in rubberpolyurethane composite or woven wire mesh.
Physical Dimensions (Typical Primary Unit): Transportable within standard highcube containers. Assembled dimensions approx.: Length 25m x Width 7m x Height 5m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression system rated for control below 10 mg/m³ at emission points.

6. APPLICATION SCENARIOS

Granite Quarry Expansion – Southeast Asia

Challenge A quarry operation needed to increase output by 60% to fulfill a new highway contract but was constrained by space limitations and a dated twostage plant with high fines production.
Solution Implementation of a compact threestage trackmounted crushing circuit featuring an advanced cone crusher in closed circuit with a tripledeck screen.
Results The new setup achieved a 65% throughput increase within the same footprint while improving yield of valuable chip products by 22%. Payback was achieved in under 14 months through the contract fulfillment.

Iron Ore Scalping & PreConcentration – West Africa

Challenge A mining operation faced high processing costs due to transporting lowgrade waste rock through the entire primary circuit.
Solution Integration of an ultraheavyduty grizzly scalper ahead of the primary crusher station to remove barren waste rock (>250mm).
Results Field data shows over 30% of total volume was rejected at the scalp level, significantly reducing energy consumption and wear in the downstream crushing stages. This increased effective plant capacity without adding new primary crushers.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Solutions are offered across three tiers:
Standard: Highefficiency base plant for common aggregate applications.
HighAbrasion: Upgraded wear packages for abrasive feeds like granite/basalt.
MiningSpec: Reinforced structures & components for heavyfeed ore applications.

Optional Features: Onboard weighing systems, automated metal detection/tramp relief systems,
remote telematics for performance monitoring,
extra dust encapsulation packages.

Service Packages: Choose from annual inspection plans,
wearsandspares contracts with guaranteed supply,
or fullsite service agreements including labor.

Financing Options: We work with export credit agencies
to provide project financing,
and offer leasetoown structures
to align payment schedules with your cash flow from project milestones.

8. FAQ

Q1 Are these plants compatible with our existing conveyors stackers?
A1 Yes within defined engineering parameters The control system can be integrated Standard discharge heights conveyor widths belt speeds are documented Our engineering team can perform a compatibility review based on your existing layout drawings

Q2 What is the expected operational impact during the transition from our old plant?
A2 With modular design the objective is minimal disruption Preassembly testing minimizes onsite commissioning A phased implementation over weeks can be planned typically allowing partial operation of your legacy system during cutover

Q3 How do you guarantee performance metrics like throughput gradation
A3 Performance guarantees are based on certified test reports using customersupplied sample materials These form part of the commercial contract Guarantees cover capacity power consumption key wear part life under defined operating conditions

Q4 What are typical lead times from order placement delivery
A4 For standard configured plants lead time ranges between months depending on model complexity Custom configurations may require additional engineering time All timelines are confirmed upon project specification

Q5 What training is provided for our operations maintenance teams
A5 Comprehensive training is included covering daily operation routine maintenance troubleshooting safety procedures Training occurs during commissioning both classroom instruction handson equipment familiarization Manuals schematics provided digitally permanently accessible