1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate production operation and facing persistent bottlenecks that erode profitability? Common challenges with conventional setups include:
Inconsistent Throughput: Fluctuations in feed material hardness or size leading to unpredictable 250300 TPH output, causing downstream delays.
Excessive Downtime: Frequent maintenance stops due to component wear or system failures, directly costing over $5,000 per hour in lost production and labor.
High Operational Complexity: Multiple standalone units requiring separate setup, calibration, and operator oversight, increasing labor costs and error potential.
Inflexible Product Specification Changes: Difficulty adapting to changing market demands for different aggregate sizes without significant reconfiguration time.

How do you achieve a steady 250300tph output with lower costperton, maximize equipment uptime, and gain the flexibility to meet varied product specs? The answer lies in a purposeengineered 250300tph stone crushing plant.

2. PRODUCT OVERVIEW

This product is a complete stationary crushing and screening solution engineered for continuous, highvolume production of aggregates. It is designed as an integrated circuit to reliably process hard rock (granite, basalt) and abrasive materials into precisely graded final products.

Operational Workflow:
1. Primary Crushing: Large feed material (up to 750mm) is reduced by a robust primary jaw crusher.
2. Secondary & Tertiary Crushing: Material is conveyed to cone crushers for further size reduction, ensuring cubical product shape.
3. Screening & Classification: Vibrating screens separate material into required size fractions.
4. Stockpiling & Conveying: Finished products are conveyed to designated stockpiles via radial stackers.

Application Scope & Limitations:
Scope: Ideal for large quarry operations, major infrastructure projects (highways, railways), and commercial concrete/asphalt plant feed. Suited for processing granite, limestone, river stone, and other similar minerals.
Limitations: Not designed for very soft or sticky materials like clay without preprocessing. Requires stable foundation and adequate electrical supply. Feed size must comply with primary crusher opening specifications.

3. CORE FEATURES

Intelligent Control System | Technical Basis: Centralized PLC with touchscreen HMI | Operational Benefit: Enables singlepoint monitoring and control of the entire 250300tph stone crushing plant flow, reducing operator workload by an estimated 30% | ROI Impact: Faster troubleshooting and optimized performance reduce nonproductive time by up to 15%

HeavyDuty Primary Station | Technical Basis: Deepchamber jaw crusher with reinforced frame and oversized bearings | Operational Benefit: Consistently handles tough feed conditions with less risk of bridging or premature wear | ROI Impact: Extended service intervals on wear parts lower maintenance costperton by an average of 18%

Hydraulic Adjustment & Clearing | Technical Basis: Integrated hydraulic systems on cone crushers | Operational Benefit: Allows operators to adjust CSS or clear cavities in minutes without manual disassembly | ROI Impact: Minimizes downtime for routine adjustments by up to 80% compared to manual systems

MultiStage Screening Precision | Technical Basis: HighG force vibrating screens with deck tensioning systems | Operational Benefit: Delivers sharp product separation and high screening efficiency even under highload conditions | ROI Impact: Reduces recirculating load and improves final product yield, maximizing saleable material output

Integrated Dust Suppression | Technical Basis: Strategically placed spray nozzles fed by a highpressure pump system | Operational Benefit: Effectively controls dust at transfer points, improving site safety and environmental compliance | ROI Impact: Avoids regulatory fines and reduces wear on machinery from abrasive dust

Modular Structural Design | Technical Basis: Prefabricated walkways, platforms, and support structures | Operational Benefit: Simplifies installation and future reconfiguration or relocation of the plant | ROI Impact: Cuts initial installation time by approximately 25%, accelerating timetoproduction

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Conventional Setup) | This 250300tph Stone Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Average Availability | 8588% (planned/unplanned stops) | Field data shows consistent >92% availability over annual cycles| +5% improvement |
| Energy Consumption per Ton| Based on disparate motor loads per unit| Optimized system design with loadsensing conveyors reduces total draw| Up to 12% more efficient |
| Wear Part Life (Primary)| Varies significantly with abrasiveness| Proprietary alloy jaws & liners demonstrate longer life in controlled tests| +2030% extended life |
| Product Shape Index (Cubicity)| Dependent on secondary stage only| Multichamber cone crushing ensures controlled fracture across stages| Improved cubicity by ~15% |
| Reconfiguration Time| Manual adjustment can take multiple shifts| Hydraulic settings allow major changes within a single shift|50% faster |

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 250 300 metric tons per hour (varies based on material density & hardness).
Primary Crusher: Jaw Crusher Model [e.g., PE900x1200], Feed Opening 900mm x 1200mm.
Secondary/Tertiary Crushers: Two units of Cone Crushers [e.g., HPC315], each with hydraulic adjustment.
Screening Units: Two sets of TripleDeck Inclined Vibrating Screens [e.g., 3YK2870].
Power Requirement: Total installed power approximately 550650 kW; requires stable industrial power supply.
Key Material Specifications: Main frame fabricated from Q345B steel; Wear plates use Mn18Cr2 highmanganese steel; Conveyor belts rated for heavy impact (EP400/3).
Approximate Footprint (LxW): ~85m x 45m (layout dependent on site specifics).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication options.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A quarry needed to increase output from 180tph to a steady 280tph to fulfill a highway construction contract but had space constraints limiting extensive new foundations.
Solution Implementation of our compact modular design for a complete stationary crushing plant allowed integration into the existing flow. The focus was on the highcapacity cone crushers for secondary/tertiary stages.
Results The plant achieved sustained throughput of >290tph of granite aggregate meeting strict ASTM specs. The modular design cut installation time by six weeks versus traditional builds.

Commercial Aggregate Supplier Diversification

Challenge A regional supplier faced fluctuating demand between concrete chips (19mm) and road base material (40mm). Changing product specs with their old multiunit setup caused fullday production halts.
Solution A new integrated circuit featuring cone crushers with rapid hydraulic CSS adjustment was installed as their primary stone crushing plant solution.
Results Changeover time between major product specifications was reduced from over eight hours to under ninety minutes. This flexibility allowed the supplier to capture spotmarket contracts profitably.

7. COMMERCIAL CONSIDERATIONS

Our solutions are offered in tiered configurations:

1. Standard Configuration Includes primary jaw crusher secondary cone crusher tertiary cone crusher screens basic conveyors dust suppression steel structure control panel
2 Premium Configuration Adds automated grease lubrication systems metal detectors magnetic separators onboard generator compatibility more comprehensive walkways
3 Customized Configuration Engineered for specific feed materials or extreme output requirements e g additional pre screening scalping unit special wear liners

Optional Features Advanced rock level sensors remote monitoring telemetry package sound enclosures heated lube systems

Service Packages We offer tiered annual service agreements covering scheduled maintenance parts discounts priority technical support Operator training programs are included with every installation

Financing Options We work with international export finance partners can facilitate leasing structures or milestone based payment plans tailored for large capital equipment purchases

8 FAQ

Q What is the lead time from order confirmation delivery?
A For standard configurations lead time is typically weeks months depending on final specifications Custom designs require additional engineering time Detailed schedules are provided upon project initiation

Q How does this plant handle variations in feed material hardness?
A The core design uses robust crushers sized above nominal capacity providing headroom Cone crushers hydraulic overload protection automatically handle momentary hardness spikes preventing damage minimizing unplanned stops

Q What are the ongoing operational costs we should budget?
A Primary costs are energy wear parts replacement labor Field data indicates average cost per ton processed factoring these elements typically ranges X Y currency units depending local power rates Regular planned maintenance is critical controlling long term costs

Q Is technical training provided our operations team?
A Yes comprehensive onsite training conducted commissioning covers daily operation routine maintenance safety procedures basic troubleshooting Documentation includes detailed operation maintenance manuals English local language requested available

Q Can we integrate existing equipment like our current primary crusher into new system?
A Engineering assessment required determine compatibility control integration conveyor interfacing Many projects incorporate one two existing major units reduce overall investment cost feasibility study can confirm this option