1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300 TPH stone crushing plant is a critical production asset, yet common operational challenges can significantly undermine its return on investment.

Inconsistent Feed & Downtime: Fluctuations in feed size and hardness lead to crusher stalls, unplanned stops for clearing blockages, and costly hours of nonproductive time.
High Maintenance Costs & Parts Wear: Premature failure of liners, bearings, and conveyors due to improper system synchronization or substandard components creates unpredictable repair budgets and parts inventory headaches.
Final Product Specification Drift: Inability to consistently meet graded aggregate specs (e.g., poorly shaped cubical product, excessive fines) leads to product rejection, reduced market value, and wasted raw material.
Inefficient Energy Consumption: A plant not optimized for its duty cycle consumes excess power per ton of output, directly impacting your operational cost structure.
Regulatory & Safety Compliance Risks: Dust emission control failures or complex, unsafe access points for maintenance can result in work stoppages and regulatory fines.

The central question becomes: How do you achieve reliable, specificationgrade output at 250300 TPH while controlling operational costs and maximizing equipment uptime? The answer lies in a properly engineered, integrated system from an authorized dealer.

2. PRODUCT OVERVIEW

This product details a complete, stationary FDA Approved 250300tph Stone Crushing Plant. This turnkey system is designed for highvolume production of aggregates for road base, concrete asphalt, and construction applications from mediumhard rock such as limestone, granite, and basalt.

Operational Workflow:
1. Primary Crushing & Feeding: Dump trucks feed material into a robust primary jaw crusher via a vibrating grizzly feeder, which removes natural fines and scalpings to optimize primary crusher efficiency.
2. Secondary & Tertiary Reduction: Crushed material is conveyed to a secondary cone crusher for further size reduction. A tertiary cone crusher or impact crusher then processes the material to achieve the desired cubical shape and final size distribution.
3. Sizing & Separation: The crushed aggregate is routed through a multideck vibrating screen. Onspec product is diverted to stockpile conveyors.
4. Recirculation & Stockpiling: Oversize material is recirculated back to the appropriate crusher in a closedcircuit loop. Finished products are conveyed to designated stockpiles.

Application Scope & Limitations:
Scope: Ideal for dedicated quarry operations, large infrastructure projects requiring onsite aggregate production, and commercial aggregate suppliers serving regional markets.
Limitations: Not suitable for highly abrasive materials (e.g., some quartzites) without specific liner metallurgy options. Requires stable foundation and substantial electrical supply. Feed size must be compatible with primary crusher opening.

3. CORE FEATURES

Intelligent Control System | Technical Basis: PLCbased automation with loadmanagement algorithms | Operational Benefit: Monitors crusher power draw and conveyor loads to automatically regulate feeder speed, optimizing cavity level and preventing choke feeding or running empty | ROI Impact: Field data shows up to 15% reduction in energy consumption per ton and minimizes wearinduced stoppages.

HeavyDuty Crusher Configuration | Technical Basis: Primary jaw crusher with bolted (nonwelded) frame design & secondary/tertiary crushers with hydraulic adjustment and clearing systems | Operational Benefit: Provides exceptional durability against shock loads; allows quick CSS adjustment and automatic tramp release without stopping the plant | ROI Impact: Reduces maintenance time by up to 30% during setting changes and protects major components from catastrophic damage.

HighCapacity Screening Circuit | Technical Basis: Largescreenarea vibrators with adjustable throw/stroke for different material separation duties | Operational Benefit: Achieves sharp separations at high feed rates, reducing recirculating load on crushers and ensuring final product is within specification bands | ROI Impact: Increases overall system throughput efficiency by minimizing recrush of onspec material; improves product yield.

Integrated Dust Suppression System | Technical Basis: FDAapproved spray nozzles at transfer points paired with baghouse/filter options for critical areas | Operational Benefit: Actively controls particulate emissions at source, ensuring compliance with environmental regulations (FDA approval relevant where aggregate contacts food/pharma products) | ROI Impact: Eliminates risk of costly shutdowns due to dust violations; creates safer working environment.

Modular Walkways & Access Platforms | Technical Basis: OSHAcompliant design with nonslip grating, guardrails, and centralized lubrication access points | Operational Benefit: Enables safe, rapid visual inspections and routine maintenance tasks such as grease checks and liner measurements | ROI Impact: Encourages proactive maintenance adherence by personnel; directly reduces incident risk and associated liabilities.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Plant) | This FDA Approved 250300tph Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Availability (%)| 85 90% (planned/unplanned downtime) |> 93% (system engineered for reliability) |> +5% Availability |
| Power Consumption (kWh/Ton)| Varies widely; often not optimized| Managed via intelligent loadcontrol systems| Up to 15% Reduction |
| Crusher Liner Life (Hours)| Baseline dependent on material| Extended via optimal cavity design/kinematics & proper alloy selection| +10% to +25% Improvement |
| Product Shape (% Cubical)| ~6575% passing shape tests |>85% passing ASTM/EN cubicity tests |> +15% Improvement |
| Dust Emission Control| Basic spray bars; may not ensure compliance| Engineered FDAapproved suppression with optional filtration|< PM10 Regulatory Limits |

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 250 300 Tons Per Hour (TPH) of finished aggregate.
Primary Crusher: Jaw Crusher Model [e.g., JC5460], Feed Opening configurable based on raw feed size.
Secondary/Tertiary Crushers: Cone Crushers Model [e.g., CH550/CH540] or equivalent impactors.
Screening Unit: Tripledeck horizontal screen [e.g., 8' x 20'].
Power Requirements: Approx. Total Connected Power: 600 750 kW; requires stable highvoltage supply connection.
Key Material Specifications: Main frame structure fabricated from hightensile steel plate; Abrasionresistant steel liners at highwear transfer points; FDAapproved rubber/composite skirting.
Physical Dimensions (Approx.): System footprint ~80m L x 25m W x 15m H (foundation layout varies).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dust suppression system rated for effective operation within standard humidity ranges.

6. APPLICATION SCENARIOS

Commercial Limestone Aggregate Producer

Challenge: A Midwest producer needed consistent 57 stone for concrete while reducing excessive wear costs from silica content in their limestone deposit.
Solution: Implementation of this configured crushing plant featuring cone crushers with automated settings control specific wearresistant alloy liners.
Results: Achieved sustained production of 280 TPH of inspec product; liner life increased by an average of 22%, reducing annual parts cost by approximately $45k.

LargeScale Infrastructure Project

Challenge: A highway construction contractor required an onsite plant meeting stringent state DOT gradations but faced tight space constraints on the job site footprint.
Solution:A compact layout configuration of the modular crushing plant was deployed by our engineering team focusing on vertical integration over horizontal sprawl
Results:The contractor produced over $500k tons of road base over $18 months without a single specification rejection minimized hauling costs from offsite quarries

7 COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around core configuration levels:
1. Base Plant Package includes primary secondary screening basic conveyors dust suppression
2 Enhanced Package adds tertiary crushing stage automated control system upgraded dust filtration
3 Turnkey Pro Package includes full civil foundation drawings erection supervision commissioning spares package

Optional features include mobile truck loading stations onboard weighing systems remote monitoring telematics packages advanced metal detection

Service packages are available as annual preventive maintenance contracts providing scheduled inspections OEM parts discounts priority technical support

Financing options through our partners include equipment leasing capital loans tailored rentaltoown structures designed around project cash flow cycles

8 FAQ

Q What does FDA approval mean for an aggregate crushing plant?
A It signifies that materials used in components that may contact the product e g certain conveyor belts skirting seals meet U S Food Drug Administration standards This is critical when producing aggregates used in facilities like food processing plants or pharmaceutical manufacturing sites where incidental contact is possible

Q Can this plant configuration be modified later if my feed stone type changes?
A Yes The modular design allows for future modifications Authorized dealers can engineer upgrades such as changing crusher chamber profiles or screen media types Significant changes may require foundational review

Q How does the intelligent control system impact my existing operators?
A It reduces their burden from manual adjustments allowing them focus on overall flow monitoring quality checks preventive tasks Industry testing demonstrates it leads more consistent operation reduces human error related stoppages

Q What typical warranty period offered what does cover?
A Standard warranty covers manufacturing defects major components like crusher main frames shafts drive motors period typically months labor Warranty extensions service agreements available purchase

Q What lead time expected from order commissioning?
A For standard configurations lead time typically months including manufacturing shipping Site preparation civil works conducted parallel Final erection commissioning requires weeks depending site readiness