1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate operation and facing consistent pressure to meet project deadlines while controlling capital and operational expenditure? The challenges of a 250300tph stone crushing plant are significant. Inconsistent feed material causes unexpected wear and downtime on critical components. Bottlenecks in one crushing stage throttle the entire line’s output, leaving capacity unrealized. Rising energy costs directly erode profit margins on every ton produced. Furthermore, frequent maintenance interrupts production schedules, and configuring a plant for multiple product specifications often requires manual adjustments and costly delays.

How do you achieve reliable 300tonperhour output without excessive maintenance overhead? Can your plant adapt to varying feed hardness and size without sacrificing final product gradation? Is your current solution delivering the expected return on investment through sustained availability and low costperton?

2. PRODUCT OVERVIEW

This product is a complete, stationary 250300tph turnkey stone crushing and screening plant designed for highvolume production of aggregates for road base, concrete, and asphalt. It is engineered for primary contractors and quarry operators requiring consistent, specificationgrade output.

Operational Workflow:
1. Primary Crushing: Large feed (≤750mm) is reduced by a robust jaw crusher or primary impactor.
2. Secondary & Tertiary Crushing: Material is conveyed to cone crushers or secondary impactors for further size reduction and shaping.
3. Screening: Multipledeck vibrating screens precisely separate crushed material into required product sizes (e.g., 05mm, 510mm, 1020mm).
4. Material Handling: A network of conveyors with centralized control transfers material between stages and to final stockpiles.
5. Dust Suppression: Integrated spray systems at transfer points control particulate emissions, ensuring environmental compliance.

Application Scope & Limitations:
Scope: Ideal for hard rock (granite, basalt), limestone, and river gravel applications. Suited for permanent installation in large quarry sites or major infrastructure project batching plants.
Limitations: Not designed as mobile or semimobile equipment. Feed size and material abrasiveness must align with configured crusher chamber selections for optimal performance.

3. CORE FEATURES

Modular Skid Design | Technical Basis: Preassembled, steelframed substructures | Operational Benefit: Reduces onsite installation time by up to 40%, ensures precise factory alignment of motors and drives | ROI Impact: Faster commissioning accelerates revenue generation; standardized modules simplify future maintenance.

Intelligent Process Control System | Technical Basis: PLCbased automation with loadsharing algorithms | Operational Benefit: Optimizes crusher feed rates in realtime to prevent choking or running empty; monitors power draw for peak efficiency | ROI Impact: Reduces energy consumption per ton by an estimated 815% and minimizes operator error.

HeavyDuty Wear Component Package | Technical Basis: Highchrome blow bars, manganese steel jaws/concaves, reinforced screen meshes | Operational Benefit: Extends service intervals by 3050% in abrasive applications, maintains consistent product gradation longer | ROI Impact: Lowers costperton for wear parts and reduces downtime frequency for component changeouts.

MultiStage Dust Control Integration | Technical Basis: Strategically placed spray nozzles with solenoid valves tied to conveyor operation | Operational Benefit: Effectively suppresses dust at each transfer point, improving site visibility and operator health | ROI Impact: Mitigates risk of environmental noncompliance fines and reduces cleanup labor.

Centralized Greasing & Lubrication System | Technical Basis: Automated pump system with distribution lines to key bearing points | Operational Benefit: Ensures critical bearings receive correct lubrication on schedule without manual intervention | ROI Impact: Prevents premature bearing failure, a leading cause of unplanned downtime.

HighCapacity Vibrating Screens with Deck Access System | Technical Basis: Large screening area with adjustable throw; integrated walkways & platforms | Operational Benefit: Maximizes screening efficiency; provides safe, easy access for mesh inspection and replacement | ROI Impact: Improves final product quality control and enhances worker safety during routine checks.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This 250300tph Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability | 8588% (including planned maintenance) | 92%+ (engineered design) | +47% uptime |
| Energy Consumption (kWh/ton)| Varies widely; often not optimized per stage| Managed via intelligent load control| Up to 15% reduction demonstrable |
| Wear Life on Abrasive Rock| Standard manganese/chrome components| Premium alloy selection & chamber optimization| +30% average increase |
| Installation & Commissioning Time| 812 weeks onsite assembly| ~57 weeks (modular skid design)| ~40% reduction |
| Product Gradation Consistency| Manual feed adjustment leads to variance| Automated setting regulation (ASRitype systems)| Variance improved by up to 25% |

5. TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: 250 300 metric tons per hour (varies based on feed material hardness & size distribution).
Primary Crusher Options: Jaw Crusher (900x1200mm) or Primary Impact Crusher (Φ1600x2000mm).
Secondary/Tertiary Crusher: Two units of Hydraulic Cone Crushers (e.g., HPC315).
Screening Stations: Two units of TripleDeck HeavyDuty Vibrating Screens (2400x6000mm).
Total Installed Power: Approximately 800 950 kW.
Key Material Specifications: Main frame structure fabricated from Q345B steel; wear liners use Mn18Cr2 or equivalent highgrade alloys.
Overall Plant Footprint (L x W): ~120m x 85m (layout can be customized).
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dust emission control meets standard regulatory limits (<20mg/m³ at property boundary).

6. APPLICATION SCENARIOS

Highway Construction Base Course Production | Challenge: A national infrastructure project required consistent supply of three graded aggregates for road base layers from highly abrasive granite. The existing plant struggled with rapid wear and inconsistent sizing, threatening project timelines.| Solution: Implementation of this heavyduty configured plant featuring cone crushers with automated settings control and premium wear packages.| Results: Achieved sustained output of 280tph. Wear part life increased by over 35%, reducing changeout downtime. Product gradation consistency met strict highway authority specifications throughout the contract.

Commercial Limestone Quarry Expansion | Challenge: A quarry expanding its market needed to increase finished product range without adding separate processing lines or excessive manual sorting.| Solution: Installation of this multistage plant with precise secondary/tertiary crushing circuits and highefficiency multideck screens.| Results:The plant reliably produces five distinct products simultaneously—from coarse aggregate to manufactured sand—at a combined rate exceeding 270tph, enabling entry into new concrete and asphalt mix markets.

7. COMMERCIAL CONSIDERATIONS

Our approach provides clarity in investment planning:

Pricing Tiers: We offer three standard configurations:
Essential: Core crushing & screening modules for reliable singleproduct output.
Advanced: Includes automation systems, enhanced dust control, wider conveyor specification.
Premium: Full turnkey package with premium wear materials package extended warranty coverage

Optional Features & Upgrades: Specific options include automated metal detection/rejection systems advanced rockonrock shaping chambers additional sound attenuation enclosures remote monitoring telematics packages

Service Packages: Choose from annual maintenance contracts providing scheduled inspections guaranteed spare parts delivery priority technical support Extended warranty plans are available covering major structural components

Financing Options: We work with established financial partners offer flexible leasing arrangements milestonebased project financing solutions tailored capital expenditure plans

8.FAQ

1.Q:What if our feed rock hardness exceeds the standard design parameters?
A:The plant's core structural design accommodates high loads but we conduct a detailed feed material analysis during quotation For extremely hard or abrasive materials we specify upgraded wear component alloys chamber geometries ensure designed throughput longevity

2.Q How does this plant manage fluctuations in incoming feed size?
A The intelligent process control system regulates feeder speeds based realtime crusher motor load preventing choking This combined surge pile capacity before primary crusher smooths out typical frontend loader variation

3.Q What typical timeframe expected from order placement commissioning?
A For standard configuration lead time manufacturing shipping approximately months Onsite installation commissioning modular skid design typically requires weeks depending local civil works readiness

4.Q Are spare parts readily available longterm?
A Yes We maintain global inventory strategic wear parts provide guaranteed stockholding agreements as part service packages All major mechanical electrical components internationally standardized brands ensuring supply chain redundancy

5.Q Can existing equipment integrated into new plant?
A Potentially yes An initial audit your current conveyors screens can determine compatibility integration feasibility often possible especially material handling equipment reducing overall project cost

6.Q What ongoing operational staffing requirements?
A The automated central control system allows efficient operation primary operators monitoring stations Additional personnel required routine mechanical checks stockpile management but labor intensity significantly lower versus manually controlled plants

7.Q What key factors influence final price quotation?
A Final pricing determined specific equipment selection required options degree site preparation needed local regulatory compliance costs shipping logistics destination Comprehensive site survey forms basis fixedprice turnkey proposal