1. PAINPOINT DRIVEN OPENING

Managing a 250300tph stone crushing plant presents distinct operational and financial challenges. Are you experiencing:
Unscheduled Downtime: Unplanned stops due to feeder blockages, crusher overloads, or conveyor misalignment, costing thousands per hour in lost production and idle labor.
Inconsistent Final Product: Fluctuations in aggregate size and shape, leading to product rejection, reduced saleable yield, and compromised contract compliance.
High Operational Costs: Spiking energy consumption from inefficient load distribution and excessive wear part replacement cycles that erode profit margins.
Bottlenecking & Inefficient Flow: Mismatched capacity between primary, secondary, and tertiary stages causing one section to wait on another, preventing the plant from achieving its designed 300tph potential.
Maintenance Complexity: Timeconsuming inspections and component changes that require extended plant shutdowns.

The central question for plant managers is: how can you achieve reliable, consistent 250300 ton per hour output while controlling operational costs and maximizing equipment uptime? The answer lies in a holistically engineered crushing plant solution.

2. PRODUCT OVERVIEW

A 250300tph stationary stone crushing plant is a complete material processing system designed for highvolume production of aggregates for construction, road base, and railway ballast. It integrates multiple stages of size reduction and classification into a synchronized workflow.

Operational Workflow:
1. Primary Crushing: Large feed material (up to 750mm) is reduced by a robust jaw crusher or gyratory crusher.
2. Secondary & Tertiary Crushing: Material is conveyed to cone crushers or impact crushers for further reduction to intermediate sizes.
3. Screening & Classification: Vibrating screens separate crushed material into specified size fractions.
4. Material Handling: A network of belt conveyors transfers material between stages and to final stockpiles.
5. Control & Monitoring: A centralized control system manages startup sequences, load balancing, and operational parameters.

Application Scope: Ideal for largescale quarry operations, major infrastructure projects requiring dedicated onsite aggregate production, and highcapacity commercial aggregate suppliers.

Limitations: This is a capitalintensive solution requiring significant site preparation, stable electrical supply (typically high voltage), and is designed for semipermanent or permanent installation. It is not suitable for highly mobile or smallscale operations.

3. CORE FEATURES

Intelligent Load Management System | Technical Basis: PLCintegrated amp monitoring with variable frequency drives (VFDs) | Operational Benefit: Prevents crusher overloads and feeder blockages by automatically adjusting feed rates | ROI Impact: Reduces unplanned downtime by up to 30% and minimizes stressrelated component failures

Modular Plant Design | Technical Basis: Bolttogether sections with standardized interfaces | Operational Benefit: Enables faster site installation (~25% less time) and future reconfiguration or expansion | ROI Impact: Lowers initial installation costs and protects longterm capital investment

Centralized Greasing & Lubrication | Technical Basis: Automated, programmable system delivering precise lubricant volumes to key bearing points | Operational Benefit: Extends bearing life by ensuring consistent lubrication; reduces manual labor requirements | ROI Impact: Cuts lubricationrelated bearing failures by an estimated 40% and associated maintenance manhours

HeavyDuty Conveyor System | Technical Basis: Impact beds at loading points, abrasionresistant belts with proper tensioning | Operational Benefit: Minimizes belt wear and spillage, ensuring consistent material flow between stages | ROI Impact: Reduces belt replacement costs and cleanup labor, directly supporting sustained 300tph throughput

Advanced Dust Suppression Integration | Technical Basis: Strategically placed nozzles with solenoid valves tied to crusher/screen operation | Operational Benefit: Suppresses dust at source points only when needed, improving site visibility and environmental compliance | ROI Impact: Reduces water consumption versus constant spraying and avoids potential regulatory fines

Unified Control Cabin | Technical Basis: Sounddampened cabin with full visualization of process flow on SCADA monitors | Operational Benefit: Provides operators with a safe, ergonomic environment to monitor the entire plant from a single point | ROI Impact: Improves operational response time by 50% and enhances personnel safety

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 250300tph Plants | Our Engineered Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Plant Availability (Monthly) | 8892% (Approx. 3540 hrs downtime)| >95% (37% increase |
| Energy Consumption per Ton Processed| Varies widely; often suboptimal load sharing| Optimized via VFDs & efficient drive trains| Field data shows 812% reduction |
| Wear Part Life in Secondary Crusher| Dependent on feed; inconsistent monitoring| Extended via load management & alloy options| Documented 1525% improvement |
| Installation & Commissioning Time| 810 weeks for full system integration| Streamlined modular design reduces this span| Approximately 25% faster deployment|
| Product Cubicity (Shape Index)| Can fluctuate with feed hardness/type| Maintained via crusher chamber optimization & settings control| More consistent output within spec |

5. TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: 250 300 metric tons per hour (tph) of crushed stone aggregate.
Primary Crusher Options: Jaw Crusher (900x1200mm) or Gyratory Crusher (4265).
Secondary/Tertiary Stage: Two units of Cone Crushers (e.g., HPC315 or equivalent).
Screening Stage: Multideck heavyduty vibrating screens (e.g., 2 sets of 2400x6000mm).
Total Installed Power Requirement: Approximately 800 1000 kW; requires stable HV grid connection.
Key Material Specifications: Primary frame constructed from highstrength steel (Q345B); Liner plates from Mn18Cr2 or equivalent; Abrasionresistant conveyor belting (minimum ST1250).
Typical Plant Footprint (L x W): ~120m x 85m (varies based on stockpile layout).
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dust emission control to meet local standards below <20mg/m³.

6. APPLICATION SCENARIOS

Large Limestone Quarry Expansion | Challenge: Existing plant capped at 200tph could not meet new contract demands for road base material; bottlenecks at secondary screening caused frequent slowdowns. Solution Implementation of a new modulardesigned crushing plant configured for consistent throughput across primary jaw crushing followed by twostage cone crushing with precise screening decks integrated into the existing flow where possible Results Achieved steadystate production of over tph of specificationcompliant product within two months of commissioning reducing reliance on subcontracting crushed material by

Major Highway Construction Corridor Challenge Required establishing multiple high volume temporary aggregate plants along the corridor with fast setup teardown times each needing reliable output Solution Deployment of semi stationary plants built on modular skid bases featuring unified control cabins pre wired connections Results Each site was operational within weeks achieving target production rates Project reporting indicated lower fuelpower costs per ton produced compared to mobile fleet alternatives meeting tight project timelines

7 COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around core configuration choices:

1 Standard Tier Includes primary jaw crusher secondary cone crushers basic screening conveyors central control panel Designed for consistent feed material Priced as a complete turnkey system
2 Enhanced Tier Adds tertiary crushing stage automated grease systems advanced dust suppression higher capacity stockpile conveyors Suited for producing more spec products or harder feed materials
3 Custom Tier Incorporates specific customer requirements such as specialized metal detection washing systems integration with existing equipment or unique layout constraints Priced upon engineering review

Optional Features High frequency fine screening decks remote monitoring diagnostics packages automated wear part measurement systems spare parts starter kits
Service Packages Comprehensive packages are available including scheduled preventive maintenance onsite technical support annual health inspections Extended warranty options can be negotiated
Financing Options Flexible commercial terms can be arranged including leasing structures milestone based project financing or traditional equipment loans through our partnered financial institutions

8 FAQ

What are the primary electrical requirements for this tph plant The system typically requires a high voltage connection kV range with total installed power draw between kW A detailed power distribution plan is part of our pre installation engineering assessment
Can this plant be configured to produce multiple aggregate specifications simultaneously Yes through strategic screen deck selection proper conveyor routing the standard design can produce up separate spec products concurrently such as base course chipsand manufactured sand
How does your solution manage variations in feed rock hardness The intelligent load management system adjusts feeder rates automatically protecting downstream crushers For extreme variations we recommend selecting specific liner profiles chamber options during the configuration phase
What is the expected timeline from order placement to full commissioning For standard tier configurations lead time is typically months followed by weeks onsite installationcommissioning subject to site readiness Custom configurations require additional engineering time
Are training services included for our operations team Yes comprehensive training covering daily operation routine maintenance safety procedures troubleshooting is provided onsite during commissioning Documentation includes detailed operating manuals parts lists schematics