1. PAINPOINT DRIVEN OPENING

Are you managing a commercial aggregate operation where consistent, highvolume output is critical to profitability? Your primary crushing circuit likely faces these persistent challenges:

Inconsistent Throughput: Feed material variations cause bottlenecks, preventing your plant from reliably hitting the 250300 tph target, leaving revenue on the table.
Excessive Downtime: Frequent mechanical failures, lengthy liner changes, and unplanned maintenance stop your entire production line, costing thousands per hour in lost output and labor.
High Operational Costs: Spiking energy consumption per ton, premature wear part replacement, and the need for constant operator intervention erode your profit margins.
Poor Product Shape & Gradation: Inconsistent output leads to excess fines or poor particle shape, reducing the market value of your finished aggregates and limiting application scope.

How do you achieve a stable 300tonperhour output with predictable operating costs and minimal disruption? The solution lies in a purposeengineered crushing plant designed not just for capacity, but for commercial reliability.

2. PRODUCT OVERVIEW

This commercial 250300tph stone crushing plant is a stationary or semistationary solution engineered for medium to largescale quarrying, mining, and infrastructure project applications. It is designed to process hard rock (granite, basalt) and abrasive materials into precisely graded aggregates (e.g., 05mm, 510mm, 1020mm).

Operational Workflow:
1. Primary Crushing: Dump feed is reduced by a robust jaw crusher or primary impactor.
2. Intermediate Screening & Crushing: Material is conveyed to a vibrating screen; oversize is routed to a secondary cone crusher for further reduction.
3. Tertiary Shaping: For premium product cubicity, a tertiary vertical shaft impact (VSI) crusher or fine cone crusher may be incorporated.
4. Final Screening & Stockpiling: Crushed material is classified on final screening decks into specified grades and conveyed to stockpiles.

Application Scope & Limitations:
Scope: Ideal for producing aggregates for concrete, asphalt, road base, and railway ballast. Suitable for integrated operation with downstream processes.
Limitations: Not designed for very soft or nonabrasive materials like limestone where simpler configurations may suffice. Requires stable foundational support and adequate electrical supply.

3. CORE FEATURES

Modular Plant Design | Technical Basis: Preassembled skid or modulebased engineering | Operational Benefit: Reduces onsite installation time by up to 30%, minimizing project delay and commissioning labor costs | ROI Impact: Faster capital deployment and revenue generation; lower civil works expenditure.

Intelligent Process Control System | Technical Basis: Centralized PLC with touchscreen HMI and motor management | Operational Benefit: Enables singleoperator control of the entire flow, optimizes crusher load for efficiency, and provides realtime fault diagnostics | ROI Impact: Reduces labor overhead; prevents costly motor failures; improves overall equipment effectiveness (OEE).

HeavyDuty Crushing Chamber Components | Technical Basis: Highgrade manganese steel castings with optimized cavity geometries | Operational Benefit: Extends wear part service life under continuous abrasive feed conditions, reducing changeout frequency | ROI Impact: Lowers costperton for consumables; increases machine availability.

Advanced Vibrating Screen with Deck Adjustment | Technical Basis: Multislope screen box with tensioned rubber or polyurethane panels | Operational Benefit: Delivers high screening efficiency (>95%) even with damp or sticky feed material, ensuring precise product separation | ROI Impact: Maximizes saleable product yield; reduces recirculating load and crusher wear.

Centralized Lube & Hydraulic System | Technical Basis: Automated grease lubrication circuits and common hydraulic power units | Operational Benefit: Ensures critical bearings and moving components receive consistent lubrication; simplifies maintenance checks | ROI Impact: Prevents catastrophic bearing failures; reduces daily manual maintenance time.

Integrated Dust Suppression System | Technical Basis: Nozzle arrays at transfer points connected to water supply with solenoid control | Operational Benefit: Effectively controls airborne particulate at primary emission sources during operation | ROI Impact: Maintains regulatory compliance; improves site working conditions and community relations.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This Commercial Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability | 8588% (including planned maintenance) | 92%+ (based on component duty ratings) | +47% availability |
| Energy Efficiency| ~1.8 2.1 kWh/ton processed| ~1.6 1.75 kWh/ton (optimized drives & load management)| Up to 12% reduction in power cost |
| Wear Part Consumption| Varies widely with abrasiveness| Documented 1520% longer life via chamber design & material spec| ~15% lower costperton |
| Setup/Reconfiguration Time| Multiple weeks for structural assembly| Dayslevel due to prewired modules & pin connections| ~60% faster deployment |
| Screening Fines Recovery| Reliant on manual adjustment & experience| Automated via loadsensing feedback loops to crushers| More consistent grade yield |

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 250 300 metric tons per hour (tph), based on material density of 1.6 t/m³.
Primary Crusher Options: Jaw Crusher (PEV900x1200) or Primary Impact Crusher (Φ1600x2000mm).
Secondary Crusher: SingleCylinder or MultiCylinder Hydraulic Cone Crusher (HPC315 or equivalent).
Power Requirement: Total installed power approximately 550 650 kW. Primary voltage supply: 380V/50Hz or 460V/60Hz.
Key Material Specifications: Main frame fabrications from Q345B steel; conveyor idlers rated CEMA C4/C5; crusher liners in Mn18Cr2 or equivalent.
Physical Footprint (Typical): ~65m (L) x 25m (W) x 15m (H). Weight varies by configuration (~180 250 tonnes).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate lubricants and weather protection.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A quarry needed to increase annual output by over half a million tons but faced space constraints and a mandate to minimize new infrastructure footprint.
Solution Implementation of this compact modular crushing plant design allowed integration into the existing flow alongside the old line during phased commissioning.
Results The plant achieved a sustained throughput of 290 tph of granite within six weeks of delivery. Product cubicity improved by over two points due to the tertiary stage VSI crusher option.

Highway Construction Material Supply

Challenge A major contractor required a guaranteed supply of multiple aggregate specifications directly at the construction site to avoid transport costs from distant quarries.
Solution Deployment of this semistationary crushing plant fed by onsite rock excavation enabled direct processing into road base (31.5mm), coarse aggregate (19mm), fine aggregate (5mm).
Results The project met all its material needs internally at an average rate of over one thousand tons per operational day while reducing hauled material costs by an estimated $3 per ton.

Recycled Concrete Aggregate Production

Challenge An urban recycling center needed higher throughput processing postdemolition concrete but struggled with frequent jamming from rebar contamination causing downtime in their existing system.
Solution This configuration utilized an impactor as primary crusher paired with an overband magnet integrated into the main conveyor system before secondary crushing stages effectively removed ferrous contaminants early in the process flow resulting in less damage downstream machinery components such as cone liners screens etcetera which are sensitive tramp metal ingress leading costly repairs production halts associated therewith .
Results Throughput stabilized at approximately two hundred seventy five tons per hour while metal removal efficiency exceeded ninety nine percent significantly protecting secondary tertiary equipment extending intervals between scheduled maintenance events .

COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around core configuration:

Tier A – Base Configuration includes primary jaw secondary cone basic screening dust suppression starting within range typical industry standard pricing .
Optional features include:
Tertiary shaping stage VSI / fine cone .
Automated metal detection removal system .
Advanced dust collection baghouse filter .
Onboard generator power pack .

Service packages available:
Standard Warranty covering defects materials workmanship twelve months .
Extended Support Plan offering scheduled inspections parts discounts priority technical support .
Full Maintenance Contract providing fixed cost coverage all wear parts consumables excluding operator damage .

Financing options can be discussed including leasetoown structures operating leases tailored fit cash flow requirements large projects .

FAQ

What if my feed material hardness exceeds typical granite specifications?
The plant's structural design accommodates higher loads however we recommend consulting our engineering team review specific rock compressive strength abrasion index possibly upgrading component specifications such as liner metallurgy bearing ratings accordingly ensure longevity .

How quickly can operational personnel learn manage this system?
Field data shows experienced plant operators become proficient basic operations within one week due intuitive control interface comprehensive training provided covers routine operation troubleshooting safety procedures .

Are spare parts readily available globally?
We maintain regional distribution centers critical wear mechanical parts ensuring lead times typically under seventy two hours domestic markets longer international shipments supported detailed documentation every component .

Can this plant be relocated once project completed?
Yes semi stationary modular design facilitates disassembly relocation subsequent sites primary steel structures conveyors designed withstand multiple assembly cycles without compromising integrity .

What are typical installation requirements from our side?
Client responsible providing suitable prepared foundation according supplied drawings adequate electrical supply connection point main distribution panel craneage offloading positioning during installation phase our team supervises mechanical electrical commissioning .