1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? In crushing and screening, common challenges directly impact your bottom line. Consider these frequent operational hurdles:
High Maintenance & Component Wear: Frequent liner changes, screen cloth replacements, and conveyor belt wear lead to substantial parts inventories and labor costs, with unscheduled stops costing thousands per hour in lost production.
Inefficient Material Flow & Bottlenecks: Poorly matched crusher and screen throughput or undersized conveyors create bottlenecks, limiting total plant capacity and leaving valuable throughput on the table.
Inconsistent Product Gradation: Outofspec aggregate products result in rejected loads, contract penalties, and wasted raw material, directly affecting revenue and client satisfaction.
Excessive Fuel & Power Consumption: Older, mechanically inefficient equipment consumes excessive energy, a cost factor that compounds daily and diminishes operational ROI.
Rigid Plant Configuration: Fixed systems struggle to adapt to changing feed material or project specifications, reducing operational flexibility and asset utilization across multiple sites.

Is your current crushing and screening equipment a source of variable cost or a driver of predictable profit? The solution lies in specifying machinery engineered to convert these pain points into measurable gains.

2. PRODUCT OVERVIEW

Our modular crushing and screening equipment is engineered for highvolume aggregate production, mineral processing preconcentration, and construction material recycling. The system integrates primary jaw crushers, secondary/tertiary cone or impact crushers, multideck vibrating screens, and material handling conveyors into a cohesive circuit.

Operational Workflow:
1. Primary Reduction: Runofquarry (ROQ) or demolition concrete is fed into a heavyduty jaw crusher for initial size reduction.
2. PreScreening & Routing: Prescreened material bypasses unnecessary crushing stages; onsize material is diverted directly to final product stockpiles via radial stackers.
3. Secondary/Tertiary Crushing: Oversize material is conveyed to cone or impact crushers for further reduction to the target product size.
4. Final Classification: Crushed material is screened on highfrequency vibrating screens into precise specification fractions (e.g., ¾” aggregate, manufactured sand).
5. Stockpiling & ReCirculation: Sized products are stockpiled; oversize is recirculated back through the circuit for closedloop operation.

Application Scope & Limitations:
Scope: Ideal for stationary quarries, largescale portable plant setups for road building, mining precrushing circuits, and centralized C&D recycling facilities.
Limitations: Not designed for smallscale (<100 TPH) operations or highly specialized applications like ultrafine grinding without supplementary processing stages.

3. CORE FEATURES

Hydroset CSS Adjustment | Technical Basis: Hydraulic piston supporting the main shaft | Operational Benefit: Closedside setting (CSS) adjustments can be made in minutes under load for optimal product size control | ROI Impact: Reduces downtime for product changeovers by up to 80%, maximizing plant utilization

Modular Frame Design | Technical Basis: Bolttogether hightensile steel sections with precision machining | Operational Benefit: Enables rapid site relocation and reconfiguration between projects | ROI Impact: Cuts mobilization time by up to 50% compared to weldedframe units

DirectDrive Crusher & Screen Mechanisms | Technical Basis: Elimination of Vbelts and complex sheaves; motortoeccentric direct coupling | Operational Benefit: Higher power transmission efficiency (up to 98%) and reduced maintenance points | ROI Impact: Lowers energy consumption by an average of 15% and reduces scheduled maintenance labor hours

Tier 4 Final / Stage V Compliant Power Units | Technical Basis: Advanced diesel engines with integrated aftertreatment systems | Operational Benefit: Full compliance in regulated regions without sacrificing power density or torque | ROI Impact: Eliminates permitting delays and ensures uninterrupted operation in environmentally sensitive markets

Centralized Greasing & PLC Control System | Technical Basis: Automated lubrication circuits with programmable logic controller monitoring all critical functions | Operational Benefit: Ensures consistent bearing protection and provides operators with realtime fault diagnostics | ROI Impact: Prevents catastrophic bearing failures; field data shows a 40% reduction in lubricationrelated component wear

AbrasionResistant Steel Liners & Components | Technical Basis: Boron steel alloys (400500 Brinell) in highwear zones like jaw dies, cone mantles, and screen side plates | Operational Benefit: Extends service life in abrasive applications like granite or slag processing | ROI Impact: Increases mean time between replacements (MTBR) by 3060%, lowering costperton for wear parts

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing & Screening Solution Documented Advantage |
| : | : | : |
| Tons per Hour (TPH) per kW/h | Varies by rock type; baseline set at 100% for comparison. Proprietary chamber designs & directdrive systems yield higher throughput per unit of energy input. Up to 15% improvement in specific energy consumption |
| Mean Time Between Failures (MTBF) Major Components| ~1,500 operating hours for crusher bearings under heavy load. Enhanced bearing housing seals & automated lube systems prevent contamination ingress. Field data supports MTBF extension beyond 2,200 hours |
| Product Shape (% Cubical) Tertiary Stage| Typically 6075% cubical aggregate from standard cone crushers. Patented multilayer crushing chamber promotes interparticle crushing. Consistent output exceeding 80% cubical product without additional shaping stages |
| Relocation & Setup Time (Modular Plants)| 57 days for partial disassembly/assembly of similar capacity plants. Integrated lifting points & preranged hydraulic/pneumatic lines streamline the process. Achieves full operational status within 34 days |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 to over 800 metric tons per hour (TPH), depending on feed material hardness (Wi) and required product gradation.
Power Requirements: Primary plant electrical demand ranges from 300 kVA to 800 kVA for electricdriven units. Dieselhydraulic configurations utilize Tier 4 Final engines from 350 kW to 750 kW.
Material Specifications: Fabricated from S355JR structural steel; highwear components utilize Hardox® or equivalent abrasionresistant steel up to HB500.
Physical Dimensions (Example Primary Module): Length: ~15m; Width: ~3m; Height: ~4m; Approximate weight: ~45 metric tons.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +50°C. Dust suppression system ready (water spray bars). Standard sound attenuation achieves below 85 dB(A) at operator stations.

6. APPLICATION SCENARIOS

Granite Quarry Expansion

Challenge A quarry operator needed to increase finished aggregate production by 35% without expanding their permitted footprint or primary electrical service infrastructure.

Solution Implementation of a new tertiary crushing circuit featuring a highspeed cone crusher paired with a tripledeck inclined screen in closed circuit configuration.

Results The new circuit optimized recirculating load management while producing more specification chip products simultaneously resulting in a measured throughput increase of output increased by an average of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase of measured throughput increase o fmeasured output increased by an average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan average o fmeasured output increased b yan averag eofmeasur edoutputincrease dofmeasur edoutputincrease dofmeasur edoutputincrease dofmeasur edoutputincrease dofmeasur edoutputincrease dofmeasur edoutputincrease dofmeasur edoutputincrease dbyanaverageof38%. Power draw per ton was reduced by12%.

Urban C&D Recycling Facility

Challenge A recycling contractor faced excessive wear costs from rebar contamination in concrete demolition feedstocks leading tounpredictable downtimeforimpactcrusherrotor repairsandhighmaintenanceexpensesforconveyorbeltsdamagedbymetallicprotrusions .

Solution A primary jawcrusherequippedwithanelectropermanentmagneticseparatoronthedischargeconveyorwasinstalledtoremoveferrousmetalsimmediatelyafterfirstcrushstagebeforematerialenteredthefinercrushingcircuit .

Results Ferrouscontaminationinthesecondarycircuitwasreducedbyover95%. Thisextendedtheservicelifeofdownstreamcrusherlinersandconveyorbeltsbyafactorofthree . Thecapturedmetallicsprovidedasecondaryrevenuestream . Overalloperatingcostpertonofrecycledaggregatewasloweredbyapproximately22%.

7 COMMERCIAL CONSIDERATIONS

Ourcrushingandscreeningequipmentispricedaccordingtocapacity , complexity ,anddegreeofautomation . Weofferthreetransparentconfigurationtiers :

• BasePerformanceTier : Highreliabilitycorecrushingandscreeningmoduleswithmanualsettingsadjustments . Idealforstablefeedconditionsandsing leproductfocus .
• HighOutputTier : Includesautomatedsettingregulation(ASRi) , largerfeedhoppers ,andheavierdutyconveyorsformaximumthroughputin demandingapplications .
• FullyMobileTrackedTier : Selfpropelledtrackedchassismodulesofferingthehighestdegreeofsite mobilityforshortdurationcontracts .

OptionalFeatures :
• DustSuppressionSystems(fogcannonorfinespray)
• AdvancedRockBreakerSystemsforgrizzlysections
• WirelessRemoteControlforcertainplantfunctions
• Onboardweighingsystemsforproductionreporting

ServicePackages :
Weoffercomprehensiveserviceagreementscoveringpreventivemaintenance , wearpartsinventoryprograms ,andpriorityfieldserviceresponse . Financingoptionsincludeoperationallease(OPEX)andcapitallease/purchase(CAPEX)solutionstailoredtoyourcompany 'scashflowrequirements .

8 FAQ

Q Whatistheleadtimeforastandardcrushingandscreeningsystem ?
A Forstandardmodularconfigurations , leadtimestypicallyrangefrom14to22weeksfromorderconfirmationtodispatch exworks . Customengineeredsolutionsmayrequireadditionalengineeringtime .

Q Howdoesyoursystemensureproductgradationconsistency ?
A Consistencyisachievedthroughacombinationoffeatures : hydrosetCSSadjustmentforprecisecrushersettingsunderload ; highGforcevibratingscreenswithefficientmeshhousingdesign ;andaPLCthatmonitorscriticalparameterstoalertoperatorstoanydeviation .

Q Areyourplantscompatiblewithexistingequipmentfromothermanufacturers ?
A Yes . Ourmodulesaredesignedwithindustrystandardinterfacesforfeedanddischargeheights . Conveyortransferpoints , electricalconnections ,anddustcontrolsystemscanbeengineeredtointegratewithyourexistinginfrastructure .

Q Whatisthetypicalinstallationandcommissioningperiod ?
A Foramodularstationaryplant , sitefoundationpreparationisrequiredinadvance . Mechanicalinstallationandelectricalhookupbyouractivatedteamtypicallyrequires710workingdaysfollowedby23daysofcommissioningandoperator training .

Q Doyouofferwearpartswarranties ?
A Yes . Wearpartslikecrusherlinersandscreenmeshescarryaperformancewarrantybasedonprocessedtonnageformaterialspecificgravitywithinagivenrange . Exacttermsareprovidedwiththetechnicalproposal .

Q Canwefinancetheequipmentthroughyourorganization ?
A Wehaveestablishedrelationshipswithseveralindustrialequipmentfinancingproviders . Wecanfacilitatecompetitivefinancingquotationsbasedonyourcompany 'sfinancialprofilefortheacquisitionofourcrushingandscreening solutions .

Q Whattrainingisprovidedforouroperatorsandmaintenancestaff ?
A Comprehensiveonsite trainingisastandardpartofcommissioning . Thisincludesdailyoperationchecks , routinepreventivemaintenanceprocedures , basictroubleshootingusingthePLCinterface ,andsafetyprotocols specifictothe equipment