1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant represents a critical production tier where inefficiencies translate into significant financial impact. Common challenges include:

Unscheduled Downtime: Frequent mechanical failures in key components can halt your entire line, costing thousands per hour in lost production and idle labor.
Inconsistent Final Product Quality: Fluctuations in grain size and shape lead to product rejection, reduced market value, and wasted raw material.
High Operational Costs: Spiking energy consumption from inefficient crushing chambers and excessive wear part replacement cycles directly cut into your margin.
Scalability Limitations: Inflexible plant layouts that cannot adapt to changing feed material or product mix requirements force costly, longterm reengineering.

Is your current setup delivering the consistent 250300 ton per hour output you designed for? Are you achieving the costperton metric required to remain competitive? The solution lies not just in machinery, but in an integrated system engineered for reliability at this specific capacity range.

2. PRODUCT OVERVIEW: 250300TPH Turnkey Stone Crushing & Screening Plant

This is a complete, stationary crushing circuit engineered for continuous, highvolume production of aggregates (05mm, 510mm, 1020mm, 2031.5mm, etc.). It is designed for primary contractors and quarry owners requiring consistent output for road base, concrete aggregate, or railway ballast.

Operational Workflow:
1. Primary Reduction: Large feed material (≤750mm) is consistently fed via a vibrating grizzly feeder to a primary jaw crusher for initial size reduction.
2. Secondary & Tertiary Crushing: The crushed material is conveyed to a secondary cone crusher for further reduction. A tertiary cone crusher or impact crusher then refines the product to the required specifications.
3. Material Screening: Multipledeck vibrating screens precisely separate the crushed material into defined product fractions.
4. Recirculation & Stockpiling: Oversize material is recirculated back to the appropriate crusher via closedcircuit conveyors, while finished products are conveyed to designated stockpiles.

Application Scope & Limitations:
Scope: Ideal for hard rock (granite, basalt), limestone, and river gravel processing. Suitable for large infrastructure projects requiring highvolume, consistent supply.
Limitations: Not designed for portable or mobile applications. Feed material with very high moisture or clay content (>10%) may require prescreening/scalping adjustments. Maximum feed size is determined by primary crusher opening.

3. CORE FEATURES

Intelligent Feed Control System | Technical Basis: Variable Frequency Drive (VFD) on feeder motors | Operational Benefit: Maintains optimal cavity level in primary crusher by automatically adjusting feed rate based on motor load | ROI Impact: Prevents crusher choking or running empty, improving throughput by up to 8% and reducing liner wear

Laminated Crushing Chamber Design | Technical Basis: Multilayer crushing principle in cone crushers | Operational Benefit: Creates interparticle compression for superior cubical product shape with reduced flakiness index | ROI Impact: Highervalue end product increases sales revenue; reduces downstream processing wear.

Centralized Greasing & PLC Automation | Technical Basis: Automated lubrication system with programmable logic controller monitoring | Operational Benefit: Ensures critical bearings receive precise lubrication intervals without manual intervention; provides fault alerts | ROI Impact: Extends bearing service life by an average of 35% and prevents catastrophic failurerelated downtime.

HeavyDuty Vibrating Screen with Wire Rope Isolators | Technical Basis: High Gforce screening motion on isolation mounts | Operational Benefit: Enables efficient separation of sticky or damp material with minimal vibration transfer to support structure | ROI Impact: Increases screen cloth life by ~25% and reduces structural maintenance costs.

Modular Conveyor System with Impact Beds | Technical Basis: Standardized bolttogether sections with reinforced load zones | Operational Benefit: Simplifies layout reconfiguration; protects belts from damage at transfer points | ROI Impact: Reduces installation time by 15% and extends conveyor belt service life significantly.

Dedicated Dust Suppression Ring System | Technical Basis: Nozzle arrays at each transfer point connected to a central pump station | Operational Benefit: Effectively controls airborne particulate at source without overwetting material | ROI Impact: Ensures compliance with environmental regulations, avoiding fines and improving site working conditions.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 250300tph Plants | Our 250300tph Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Availability (Scheduled Hours) | 90 92% | ≥ 95% (Documented) | +3 to +5 percentage points |
| Power Consumption per Ton Processed| ~1.8 2.0 kWh/t (Hard Rock)| ~1.65 1.75 kWh/t (Hard Rock)| 8% to 12% |
| Wear Part Cost per Ton (Cone Liners)| Industry Average Index = 100| Index = 85 90| 10% to 15% |
| Product Flakiness Index (Tertiary Stage)| >15% common target range| Consistently <12% target range| +20% improvement in shape |
| Installation & Commissioning Time| ~4560 days from delivery completion| ~3040 days from delivery completion| 25% to 33% |

5. TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: Nominal output of 270 tph, configurable between 250 – 300 tph based on final screen deck configuration and feed material hardness.
Power Requirements: Total installed power approximately 550 – 650 kW. Requires main power supply at 400V/50Hz or customized. All major motors equipped with soft starters.
Material Specifications: Primary crusher frame constructed from welded steel plate (≥ Q345B). Wear liners use Mn18Cr2 or equivalent highchromium alloy steel. Conveyor belts rated for minimum EP400/3.
Physical Dimensions (Typical Layout): Entire plant footprint approximately 85m (L) x 45m (W) excluding stockpiles. Maximum height (~22m) at primary crusher feed hopper.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust emission control achieves ≤30mg/m³ at property boundary with active suppression system engaged.

6. APPLICATION SCENARIOS

Highway Construction Project Aggregate Supply

Challenge: A contractor needed guaranteed daily supply of multiple certified aggregate sizes (0/5mm sand substitute, two grades of base course) for a timecritical highway project exceeding one million tons total demand.
Solution Implementation of this standardized yet configurable stone crushing plant allowed parallel production lines within the same footprint.
Results The plant met the required daily volume consistently over an eighteenmonth period while maintaining strict gradation specifications across all products as verified by project QC labs.

Granite Quarry Expansion

Challenge An existing quarry operation sought to increase its marketable product range beyond simple base material into highervalue concrete aggregates but was constrained by an outdated singleline setup producing inconsistent grain shape.
Solution This modular stone crushing plant was integrated as a second dedicated line featuring advanced tertiary crushing stages specifically tuned for granite's abrasive properties.
Results The quarry added three premium aggregate products to its catalog within six months of commissioning achieving an average sales price increase of €2 per ton while maintaining throughput above the targeted minimum threshold

7 COMMERCIAL CONSIDERATIONS

Our approach provides clarity on investment options:

Pricing Tiers:
Tier A Base Plant Configuration Includes primary secondary tertiary crushing core screening basic dust control Designed as reliable workhorse solution
Tier B Enhanced Configuration Adds automated greasing advanced PLC control system upgraded dust filtration optional features like metal detectors
Tier C Fully Optimized Configuration Incorporates all Tier B features plus remote monitoring diagnostics predictive maintenance software package highest grade wear materials

Optional Features:
Onboard power generation package diesel over electric
Automated sampler systems integrated into final product conveyors
Additional finished product conveyor stackers radial type
Extended warranty coverage up years on major structural components

Service Packages:
Standard Package Commissioning operator training first year scheduled inspections
Premium Package Includes standard plus annual comprehensive health check prioritized spare parts dispatch guaranteed response times hours
Platinum Package Full maintenance contract covering all scheduled servicing wear parts excluding consumables like screen cloths based on agreed costperton model

Financing Options:
We offer structured financing solutions through our partners including equipment leasing longterm rental purchase agreements PPA models tailored cash flow requirements typical project timelines

FAQ

What if my raw feed material hardness changes frequently?
The stone crushing plants core cone crushers are equipped hydraulic adjustment systems allowing operators quickly change CSS closed side setting minutes compensate different rock characteristics maintain consistent output quality

How does this system integrate with my existing frontend loaders feeding?
The design includes surge hopper capacity approximately tons buffer ensuring continuous operation even during short breaks loader cycle times Standard feed hopper width accommodates all common wheel loader bucket sizes

What are typical lead times from order placement commissioning?
For standard configurations lead time typically months exworks Customized layouts may require additional weeks Detailed project schedule provided upon initial technical review

Do you provide performance guarantees?
Yes we provide contractual performance guarantees covering minimum throughput capacity maximum power consumption key product gradation curves based agreed test protocol using your site representative sample materials prior shipment

What ongoing technical support available after commissioning?
Support includes access online parts catalog technical drawings video library Our service engineers available remote diagnostics phone email For critical issues we maintain network certified technicians regions worldwide