1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and contractors, the primary crushing and screening stage often dictates overall site efficiency. Common challenges include:
Unscheduled Downtime: Frequent mechanical failures in crushers or screeners halt the entire processing line, costing thousands per hour in lost production and labor.
Inconsistent Product Gradation: Outdated or poorly configured screening equipment fails to separate material precisely, leading to offspec product, recrushing cycles, and wasted capacity.
High Maintenance Burden: Equipment with complex lubrication systems or difficulttoaccess wear parts consumes excessive maintenance hours and drives up spare parts inventory costs.
Energy Inefficiency: Older crushing chambers and drive systems draw more power per ton processed, making energy a disproportionately high variable cost.
Rigid Plant Layouts: Fixed chassis systems limit operational flexibility, making it difficult to adapt to changing feed material or project requirements.

Is your current bulk crushing and screening equipment a source of constant reactive management? What would a 1520% improvement in overall equipment effectiveness (OEE) mean for your annual output?

2. PRODUCT OVERVIEW: Bulk Crushing And Screening Equipment

Our engineered solutions are modular and stationary bulk crushing and screening plants designed for highvolume primary and secondary reduction of aggregate, ore, and demolition materials. The operational workflow is engineered for continuous flow:
1. Primary Feeding & Scalping: Dumpfed material is directed to a vibrating grizzly feeder, which removes fines and bypasses subsize material to optimize primary crusher loading.
2. Primary Size Reduction: A robust jaw or gyratory crusher performs the initial breakdown of large feed (up to 1200mm) into manageable sizes.
3. Primary Screening & Conveying: Crushed output is conveyed to a primary screen (e.g., heavyduty inclined screen) for initial separation into multiple product streams.
4. Secondary Processing: Oversize material is recirculated via closedloop conveyor to a secondary cone or impact crusher for further reduction before returning to the screen.
5. Final Product Stockpiling: Correctly sized fractions are conveyed to designated stockpiles as saleable product.

Application Scope: Ideal for largescale quarrying, mining precrushing, major infrastructure projects requiring onsite aggregate production, and highvolume construction & demolition recycling.
Key Limitations: Not designed for smallbatch or pilotscale operations. Site requires sufficient space for plant layout, feed access, and product stockpiling. Optimal performance assumes professional operation and adherence to prescribed maintenance schedules.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Highinertia vibrator mechanism with adjustable grizzly bar spacing | Operational Benefit: Regulates feed rate to the primary crusher, eliminates bridging, reduces crusher shock loads by scalping out fines | ROI Impact: Extends crusher liner life by up to 30% and prevents costly chokefeeding damage

Hydroset Crusher Adjustment System | Technical Basis: Hydraulic cylinders support the main shaft & adjust the crusher setting under load | Operational Benefit: Allows operators to change product size or clear blockages in under 10 minutes without stopping the crusher | ROI Impact: Minimizes downtime for CSS adjustments by over 90% compared to manual shim systems

Modular Screenbox Design | Technical Basis: Bolttogether subframes with interchangeable deck types (wire mesh, polyurethane, punch plate) | Operational Benefit: Enables rapid media changeout (<4 hours) and future reconfiguration for different products without replacing entire unit | ROI Impact: Reduces screen deck inventory costs by 25% through standardization

Centralized Greasing & Lube System | Technical Basis: Automated singlepoint lubrication circuits with flow monitors for all major bearings | Operational Benefit: Ensures critical components receive correct lubrication on schedule; alerts operators to flow failures | ROI Impact: Prevents an estimated 70% of premature bearing failures, a leading cause of unplanned stoppages

PLCBased Plant Control System | Technical Basis: Programmable Logic Controller with touchscreen HMI monitoring motor loads, temperatures, and production totals | Operational Benefit: Provides operators with realtime visibility of plant performance and facilitates smooth startup/shutdown sequences | ROI Impact: Enables datadriven decisions; field data shows a typical 58% increase in throughput through optimized sequencing

AbrasionResistant Material Flow Paths | Technical Basis: AR400 steel liners at all highimpact transfer points and reinforced conveyor skirts | Operational Benefit: Protects structural steel from wear, maintaining material containment and preventing leakageinduced cleanup | ROI Impact: Reduces structural repair work during the plant's lifecycle by an estimated 40%

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Bulk Crushing And Screening Solution | Documented Advantage |
| : | : | : | : |
| Crusher Availability (Scheduled Runtime) | 9294% | 9698%+ | +4% improvement |
| Tons per Kilowatthour (t/kWh) Efficiency| Varies by rock type; Baseline = 1.0x | Up to 1.18x baseline via optimized chamber design & drive train| Up to 18% energy saving |
| Mean Time Between Failure (MTBF) Key Bearings| ~2,000 operating hours| >3,200 operating hours| >60% longer service life |
| Screen Media ChangeOut Time (Full Deck)| 68 hours (welded frames)| <4 hours (modular boltin)| Up to 50% time reduction |
| Overall Noise Emission at 10m Distance| ~110 dBA| 5 dBA reduction |

5. TECHNICAL SPECIFICATIONS

Design Capacity Range: Configurable from 400 TPH to over 2,000 TPH nominal throughput.
Primary Crusher Options: Jaw Crushers (Feed opening up to 1500x1200mm) or Primary Gyratory Crushers.
Secondary/Tertiary Crusher Options: Heavyduty cone crushers with multiple cavity options.
Screening Units: Multideck vibrating screens from 2.4m x 6m up to 3m x 10m; linear or elliptical motion available.
Power Requirements: Total installed plant power typically ranges from 450 kW to 1.5 MW; supplied for 400V/50Hz or 480V/60Hz operation.
Key Material Specifications: Main frame structure: S355JR steel; Wear liners: AR400/AR500 steel; Screen decks: Hightensile steel frame with userspecified media.
Typical Physical Footprint (Modular Stationary Plant): Approximately 35m (L) x 22m (W) x 15m (H), subject to configuration.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system ready; standard paint system protects against C3 corrosion class.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A quarry needed to increase base course production by 60% but had limited space for a new processing line footprint.The existing plant suffered from low availability due to frequent conveyor jamsand complex maintenance procedures.

Solution Implementation of a compact,bulk crushingand screeningplant featuringa steep feed conveyor,a single primary jawcrusher,and adirectly coupled tripledeck screenwith integrated recirculation.Conveyor transfer points were minimized.

Results The streamlined layout reduced the required footprintby25%.The simplifiedmaterial flowincreased plant availabilityto97%.The site achievedthe target60% throughputincrease while reducingoperational laborcostsby two FTEsdue toeasier monitoringand maintenanceaccess.

Major Urban Infrastructure Recycling

Challenge A contractor on a large ring road project was mandatedto reuse95%of demolished concreteonsite,butthefeedmaterialwas highlyvariableand contaminatedwith rebar.

Solution A bulkcrushingandscreeningplant was configuredwithan electromagneticoverband separatoron thefeedconveyorandaprimaryimpactcrusheroptimizedfor concretebreaking.Thesecondarystage includedarobustscalper screento removefine soilsandunwantedfines.

Results The plantsuccessfullyprocessedover1.2milliontonsof demolitiondebris.Contaminationin therecycledaggregatewas keptbelow0.5%,meetingstrict specifications.Ownsite recyclingeliminatedlandfillcostsand reducedinboundvirginaggregatehaulagebyover80%,securingtheproject's sustainabilitybonuses.

7.COMMERCIAL CONSIDERATIONS

Our bulkcrushingandscreeningequipmentis offeredin tieredconfigurations:

• Standard Duty Range(Up To600TPH):For consistentfeed materialslike limestoneor cleanaggregate.Pricedasacompletepackagewithcorefeatures.

• Heavy Duty Range(600–1，200TPH):For abrasive materials(granite，basalt)andhighavailabilityrequirements.Includesupgradedwear packagesandmorecomprehensivecontrolsystems.Premiumpricingreflectsincreasedmaterialspecifications.

• Extra Heavy Duty/Mining Range(1，200+TPH):Engineeredfor24/7primarycrushingapplicationsin miningor megainfrastructureprojects.Fullycustomized，oftenquotedonaprojectbasis.

Optional Features：Dust suppressioncannonsystems，acousticenclosures，advancedpredictivemaintenancesensors( vibration，thermal)，automatedwearpartmeasurementsystems，extendedconveyors。

Service Packages：We offer tiered supportfrombasiccommissioningandoperatortrainingto comprehensiveannual inspectionplansandoncalltechnicalsupportwithguaranteedresponse times。

Financing Options：To aid capital planning，we can facilitateoperatingleaseagreements,tailoredrentaltoownprogramsforprojectduration，orfixedtermfinancingthroughpartner institutions。

8.FAQ

Q：Can thisbulkcrushingandscreeningequipmentintegratewithexistingconveyorsandsurge piles？
A：Yes。Ourplantsareengineeredformodularintegration。Thecontrolsystemcanbeconfiguredtointerfacewithexistingupstreamfeedingordownstreamstockpilingsystems。Interfaceengineeringisastandardpartofourpresalesreview。

Q：Whatisthetypicalleadtimefromorderto commissioning？
A：Forstandardrangeconfigurations，leadtimesaveragebetween26and34weeks，dependingoncurrentfoundrycapacitiesforcastcomponents。Heavydutycustomconfigurationsrequireadetailedengineeringphase。

Q：Howdoestheenergyconsumptioncompareto retrofittingolderindividual machines？
A：Fielddataconsistentlyshowsa12–20%savinginkWhpertonprocessed。Thisisachievedthroughoptimizeddrivetrainselection ，directcouplingwherepossibletoreduce transmissionlosses ，andefficientcrusherchambergeometries thatreduce thenumberofcrushingstagesrequired。

Q：Arewearpartsproprietary ，oraretheystandardized？
A：We usestandardizedbearinghousings ，seals ，andmany mechanicalcomponents 。Crucialwearpartslikecrusherlinersandscreenmediaareengineeredforspecificperformancebutaremanufacturedtomachinespecificdrawingsavailabletoyou；youarenotlockedintoasinglesource 。

Q：Whattrainingisprovidedforouroperatorsandmaintenanceteam？
A ：We includeacomprehensiveonsitetrainingprogramduringcommissioningcoveringnormaloperation ，troubleshootingalarms ，dailychecks ，androutinepreventativemaintenanceprocedures 。Fulldocumentationincludingpartsmanualsandelectricalschematicsisprovided 。

Q ：Isperformanceguaranteed？
A ：Yes 。We providecontractualguaranteesfortonnage throughput（basedonagreedfeedmaterialspecifications），productgradation ，andpowerconsumption 。Thesearevalidatedduringtheacceptancetestatourfacilityorbeforecommissioningonyoursite 。

Q ：Whatistheexpectedservicelifeforthemainstructuralcomponents？
A ：Themainchassis ，crusherframes ，andscreenboxesaredesignedforaminimumservice lifeof25+yearsundernormaloperatingconditions 。Strategicuseofreplaceablewearlinersprotectsthestructuralintegritythroughoutthislifecycle 。