1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the crushing phase is often the primary bottleneck. Common challenges include:
Excessive Downtime for Maintenance: Frequent liner changes, bearing failures, and unexpected breakdowns can halt your entire production line for days, costing thousands per hour in lost output.
Inconsistent Product Gradation: Fluctuations in feed material or machine performance lead to offspec aggregate, resulting in product rejection, recrushing costs, and dissatisfied customers.
Unscheduled Operational Costs: Spare part consumption, high energy use per ton processed, and laborintensive adjustments create financial uncertainty.
Regulatory and Safety Compliance Risks: Managing dust emissions, noise levels, and equipment safety to meet stringent site and environmental regulations adds complexity and potential liability.

What if your primary crushing station could deliver predictable throughput with lower operational expenditure? The solution lies in specifying equipment engineered for reliability and efficiency from the ground up.

2. PRODUCT OVERVIEW

The FDA Approved Stone Crusher Plant refers to a stationary or semimobile crushing and screening system where all electrical components, motor assemblies, and lubrication systems utilize FDAapproved materials for specific applications. This is critical for operations where processed stone may contact consumable products, such as in agricultural lime or certain industrial fillers. The core of the plant is a heavyduty jaw crusher or primary impactor designed for highabrasion environments.

Operational Workflow:
1. Primary Reduction: ROM (RunofMine) feed material is dumped into a vibrating grizzly feeder, which bypasses fines and directs oversize to the primary crusher.
2. Crushing & Sizing: The primary crusher reduces material to a conveyable size. Critical contact parts are constructed with alloys compatible with FDA standards where required.
3. Material Transfer & Screening: Crushed stone is conveyed to a screening unit where it is separated into precise product fractions.
4. Stockpiling or Secondary Crushing: Onspec material is routed to stockpile conveyors; oversize may be recirculated through a secondary cone or impact crusher for further reduction.

Application Scope & Limitations:
Scope: Ideal for quarrying limestone, granite, basalt, river gravel; production of aggregate for construction, road base; processing of agricultural lime; specialized industrial mineral preparation.
Limitations: Not designed for metallic ore processing or highly plastic/claybound materials without significant preprocessing. Maximum feed size and hardness are constrained by modelspecific engineering limits.

3. CORE FEATURES

Patented Liner Retention System | Technical Basis: Hydraulic cylinder adjustment and locking mechanism | Operational Benefit: Enables liner changes in under 2 hours without manual backing bar removal | ROI Impact: Reduces downtime by up to 70% per changeout cycle versus traditional wedge systems

Intelligent Load Management | Technical Basis: PLCcontrolled variable frequency drive (VFD) paired with pressure sensors | Operational Benefit: Automatically regulates feed rate based on crusher motor amperage, preventing overloads and tramp metal damage | ROI Impact: Protects major components from catastrophic failure; field data shows a 40% reduction in unplanned stoppages

FDACompliant Lubrication Circuit | Technical Basis: Sealed lubrication system using NSF/H1/FDAapproved greases & oils | Operational Benefit: Eliminates risk of product contamination in sensitive applications; extends bearing life with superior antiwear additives | ROI Impact: Meets stringent industry certification requirements; reduces bearingrelated failures by an average of 30%

Modular Wear Component Design | Technical Basis: Symmetrical wear part geometry & standardized mounting | Operational Benefit: Allows rotation of wear parts like jaw dies for extended service life; simplifies inventory management | ROI Impact: Increases wear material utilization by up to 50%, lowering costperton for consumables

Integrated Dust Suppression Manifold | Technical Basis: Preplumbed nozzle system at key transfer points with flow control valves | Operational Benefit: Provides effective dust control from initial feed point without requiring field fabrication | ROI Impact: Ensures immediate compliance with environmental regulations; reduces water usage by targeting spray precisely

Centralized Greasing Point | Technical Basis: Singlepoint connection linking all major bearing lubrication points | Operational Benefit: Enables safe, rapid routine maintenance from one groundlevel station during operation pauses | ROI Impact: Increases scheduled maintenance adherence by operator crews by an estimated 25%, enhancing longterm reliability

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our FDA Approved Stone Crusher Plant Solution Documented Advantage |
| : | : | : |
| Availability (Uptime) | 8590% (Scheduled & Unscheduled) >92% Sustained Availability
Advantage: +1525% reduction in lost production time |
| Cost per Ton (Wear Parts) Based on abrasive granite feed $0.85 $1.10/ton $0.65 $0.75/ton
Advantage: Up to 30% lower consumable cost |
| Energy Consumption Average kWh/ton processed Industry testing demonstrates 812% improvement
Advantage: 812% lower power draw via optimized kinematics & VFD |
| Setup/Reconfiguration Time For modular plants requiring relocation Multiple skidmounted modules with prerigged connections
Advantage: 40% faster site deployment |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 200 800 TPH (Tons Per Hour), depending on model configuration and feed material.
Primary Crusher Options: Jaw Crusher (42”x60” to 56”x72”) or Horizontal Shaft Impactor (48”x60” rotor).
Power Requirements: Main crusher drive from 300 HP to 600 HP; total plant connected power typically 600 1200 kW.
Material Specifications: Crusher frame fabricated from highstrength steel plate (ASTM A36/A572); Liners available in multiple grades of manganese steel (14%,18%,22%); FDAcompliant contact surfaces available upon request.
Physical Dimensions (Typical Primary Module): Length ~18m, Width ~5m, Height ~6m. Weight approximately 95130 metric tons.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C (4°F to +122°F). Dust suppression system rated for operation up to 95% relative humidity.

6. APPLICATION SCENARIOS

Agricultural Lime Production Facility Challenge Required consistent production of fine aglime while ensuring zero risk of oil or grease contamination from machinery contacting the final product Solution Installation of a complete primary & secondary crushing circuit featuring sealed bearings and an FDAcompliant lubrication system throughout Results Achieved certified product purity for direct application on farmland while increasing plant throughput by 22% due to higher crusher reliability.

Urban Quarry Operating Under Strict Regulations Challenge Needed to significantly reduce particulate emissions (PM10/PM2.5) and noise levels to comply with new city ordinances near residential zones Solution Deployment of our stone crusher plant with integrated dust suppression manifold housed within acoustic cladding panels Results Particulate emissions reduced by over 95%, meeting regulatory thresholds without auxiliary equipment costs.

Road Base Contractor with Multiple Sites Challenge High mobilization costs and extended setup times when moving equipment between temporary quarry sites over a threeyear highway project Solution Utilization of our skidmounted modular plant design with preassembled electrical interconnects Results Reduced average site setup time from ten days to six days per relocation, saving an estimated $18k per move in labor and equipment rental.

7. COMMERCIAL CONSIDERATIONS

Our pricing structure is based on a modular configuration approach:
Base Tier Plant: Includes primary crusher module, feeder module basic discharge conveyor standard electrical controls
Enhanced Tier Plant: Base tier plus integrated dust suppression onboard hydraulic systems advanced automation package
Full Circuit Tier Plant Enhanced tier plus secondary crushing module screening tower additional radial stackers

Optional features include:
Automated wear part monitoring sensors
Remote telematics package
Winterization kits
Customized discharge heights

We offer comprehensive service packages ranging from annual inspections through fullsite operation support Financing options including capital lease operating lease project financing are available through our partners subject credit approval

8.FAQ

Q What does 'FDA Approved' specifically refer within this stone crusher plant?
A The designation applies specifically lubricants seals gasket materials any component that could potentially contact processed stone applications requiring foodgrade certification such agricultural lime These components meet FDA Title CFR requirements Machinery itself not 'approved' but built specifications that prevent contamination

Q How does this plant integrate existing screening conveying infrastructure?
A Our plants are engineered standard interface dimensions can be adapted via custom chutework transition sections Engineering team will review your existing layout provide detailed integration drawings ensure compatibility prior fabrication

Q What typical expected operational lifespan major components?
A With proper maintenance per our schedule structural frames are designed minimum year service life Major rotating assemblies like shafts bearings have documented service intervals exceeding operating hours Liner life varies materially but our design maximizes utilization before replacement required

Q Are spare parts readily available what lead times should we anticipate?
A We maintain strategic inventory critical wear parts common consumables at regional service centers Standard parts typically ship within hours For major fabricated components lead times vary weeks depending complexity current order book we provide transparent forecasts upon request

Q Do you provide installation commissioning support?
A Yes we offer tiered commissioning packages ranging from supervisory oversight where your team performs installation full turnkey erection managed our certified field engineers Scope defined contract phase ensure clear responsibilities