1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, the crushing and screening circuit is often the bottleneck where profitability is won or lost. Key challenges include:
Unscheduled Downtime: Bearing failures or component wear can halt an entire production line, costing thousands per hour in lost output and labor.
High Maintenance Costs: Frequent liner changes, conveyor adjustments, and reactive repairs consume both budget and valuable technician hours.
Inconsistent Product Yield: Improper sizing or contamination forces material to be reprocessed, wasting energy and reducing saleable product volume.
Rising Energy Consumption: Inefficient drives and poorly optimized material flow lead to power costs that directly impact your costperton metric.
Rapid Equipment Wear: Abrasive feeds and highimpact loads degrade critical components faster than anticipated, shortening asset life.

Is your operation equipped to overcome these challenges? The solution lies not just in machinery, but in selecting engineered crushing and screening equipment designed for total cost of ownership.

2. PRODUCT OVERVIEW

The modern crushing and screening plant is a coordinated system of primary crushers, secondary/tertiary crushers, vibrating screens, and conveyors. Its operational workflow is designed for continuous material reduction and classification:
1. Primary Reduction: Raw feed material is introduced to a robust primary crusher (e.g., jaw or gyratory) for initial size reduction.
2. Secondary/Tertiary Crushing: Material is conveyed to cone or impact crushers for further refinement to the desired particle size.
3. Sizing & Separation: Crushed material is fed onto vibrating screens with specific mesh apertures to separate it into graded products (e.g., aggregates, chips, fines).
4. Stockpiling & Recirculation: Onspec material is conveyed to stockpiles. Oversize material is automatically recirculated back into the crusher circuit for further processing.

This equipment is essential for quarrying, mining, construction demolition recycling, and aggregate production. Limitations include requirements for stable foundational support, controlled feed size distribution, and adherence to planned maintenance schedules.

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Computermodeled kinematics & optimized nip angles | Operational Benefit: Delivers a consistent product curve with fewer flaky aggregates | ROI Impact: Increases saleable product yield by up to 8%, reducing waste

Hydroset CSS Adjustment | Technical Basis: Hydraulic piston for closedside setting (CSS) control | Operational Benefit: Allows operators to adjust crusher discharge setting in under 60 seconds for different product specs | ROI Impact: Minimizes downtime for product changeovers, increasing annual utilization

Modular Wear Component System | Technical Basis: Interchangeable liner segments with reversible designs | Operational Benefit: Reduces liner changeout time by up to 40% and extends service intervals | ROI Impact: Lowers labor costs per ton and reduces inventory holding costs for spare parts

DirectDrive Crusher & Screen Technology | Technical Basis: Elimination of Vbelts, sheaves, and fluid couplings | Operational Benefit: Improves power transmission efficiency by approximately 5% and reduces maintenance points | ROI Impact: Directly lowers kWh per ton energy costs and associated drive component inventories

Centralized Greasing & PLC Automation | Technical Basis: Automated lubrication cycles & programmable logic controller with touchscreen HMI | Operational Benefit: Ensures optimal bearing lubrication regardless of operator shift change; provides realtime throughput monitoring & fault diagnostics | ROI Impact: Prevents costly bearing failures (the 1 cause of crusher downtime) and optimizes feed rates for peak efficiency

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Crushing & Screening Solution | Advantage (% improvement) |
| : | : | : | : |
| Availability (Uptime) | 8892% scheduled runtime | >95% scheduled runtime demonstrated in field trials| +4% to +7% |
| Cost Per Ton (Operating)| Based on reactive maintenance & standard efficiency drives| Engineered for predictive maintenance & highefficiency direct drives| Reduction of 1215% documented |
| Liner Change Time (Primary Crusher)| 1824 hours crew time| <12 hours with modular system design| Time savings of ~40% |
| Energy Consumption (kWh/ton)| Baseline set by conventional drive systems| Reduced via direct drive & optimized chamber design| Improvement of 57% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 TPH fixedplant setups to 1,500+ TPH trackmounted or stationary modular plants.
Power Requirements: Plantwide requirements from 400 kVA to over 1.5 MVA; designed for connection to grid or prime power gensets.
Material Specifications: Crusher jaws/mantles manufactured from M2 (22% manganese steel) or proprietary martensitic alloys; screen decks in hightensile steel or polyurethane.
Physical Dimensions (Example Primary Station): Feed hopper capacity: 8m³; Crusher unit weight: ~26,000 kg; Overall length for transport: ~15m.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dustsealed bearings and IPrated electrical components standard.

6. APPLICATION SCENARIOS

Granite Quarry Operation | Challenge: High silica content causing excessive wear on cone crusher liners every 450 hours, leading to frequent stoppages and high consumable costs. | Solution: Implementation of a tertiary cone crusher with patented chamber geometry and advanced martensitic alloy liners. Integration of an automated greasing system specific to the dusty environment.| Results: Liner life extended to over 700 hours. Combined with reduced changeout time, this yielded a 22% reduction in costperton for consumables in the first year.

Construction & Demolition Recycling Yard | Challenge: Inconsistent feed material (rebar, wood contaminants) causing screen blinding and downstream conveyor damage from uncrushables.| Solution: Deployment of a heavyduty primary jaw crusher with hydraulic toggle release system alongside a robust scalping screen with aggressive stroke action.| Results: The hydraulic release cleared tramp metal without shutdowns within seconds. Screen blinding was reduced by over 60%, maintaining consistent throughput targets despite variable feedstock.

7. COMMERCIAL CONSIDERATIONS

Crushing and screening equipment pricing follows distinct tiers based on capability:
Standard Production Tier: Highvalue fixed configurations offering proven performance at competitive capital cost.
HighAvailability Tier: Includes premium features like automation packages, advanced wear monitoring sensors, extended component warranties.
Modular/Mobile Tier: Trackmounted or wheeled skid designs focused on rapid deployment/redeployment between sites.

Optional features include dust suppression systems tiered by water consumption rates (liters/minute), remote telematics packages providing fleet health data via satellite/cellular networks.

Service packages range from basic scheduled maintenance plans through comprehensive fullcircuit performance contracts guaranteeing uptime percentages.

Financing options are available through our capital partners including operating leases tailored to seasonal cash flows or traditional installment sales agreements.

8. FAQ

Q1. Is your equipment compatible with our existing conveyors stackers?
Our crushing stations are engineered with industrystandard discharge heights belt widths We provide detailed interface drawings during the quotation phase ensure seamless integration into your current layout

Q2. What kind of production increase can we realistically expect?
Field data shows improvements depend on your current setup For operations using decadeold technology typical gains range from % throughput increase due higher availability more efficient crushing action

Q3. How does the automation system impact our existing workforce?
The PLC automation handles process optimization diagnostics freeing your skilled operators focus on overall plant management quality control rather than manual adjustments It represents skillset enhancement not replacement

Q4. What are typical lead times delivery?
For standard plant configurations lead times average months Custom engineered solutions may require longer based scope Engineering procurement teams provide detailed project timeline upon application review

Q5. Are performance guarantees offered?
Yes we offer guaranteed minimum throughput capacity product gradation curves based certified feed analysis These form part commercial agreement subject standard site operating conditions

Q6. What does the service support network look like?
We maintain regional technical centers stock critical spare parts Our certified technicians available both scheduled maintenance emergency breakdown support Service level agreements define response times resolution targets