1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and engineering contractors, the crushing and screening circuit is often the bottleneck. Common challenges include:
Excessive Downtime for Maintenance: Frequent liner changes, bearing failures, and conveyor issues halt your entire production line, costing thousands per hour in lost throughput.
Inconsistent Product Gradation: Offspec material leads to rejected loads, reprocessing costs, and dissatisfied clients, directly impacting profitability.
High Operational Costs: Rising energy consumption, high wear part replacement rates, and the need for multiple operators strain your budget.
Rigid Plant Configuration: Inflexible setups cannot adapt to changing feed material or product requirements, forcing suboptimal operation or capital expenditure on new equipment.

What if your primary crushing station could deliver greater throughput with less unplanned stoppage? How would predictable final product sizing improve your bottom line? The solution lies in specifying equipment engineered to address these exact pressures.

2. PRODUCT OVERVIEW

The [Manufacturer Name] mobile primary crushing and screening plant is a trackmounted, fully integrated system designed for the initial size reduction and scalping of quarry rock, recycled concrete, and medium abrasive ores. Its operational workflow is engineered for simplicity and efficiency:
1. Feed & PreScreen: Runofquarry material is loaded into the hopper. An independent prescreen removes fines prior to the crusher, reducing wear and increasing capacity.
2. Primary Crushing: Material is conveyed to the heavyduty jaw crusher for initial reduction.
3. PostCrushing Screening & Sorting: Crushed material is conveyed to the onboard screenbox, separating it into specified product fractions (e.g., base course, aggregates) and oversize.
4. Stockpiling & Recirculation: Onsize product is stockpiled via radial conveyors. Oversize can be recirculated back to the crusher in a closedloop circuit or diverted.

Application Scope: Ideal for largescale quarrying, virgin aggregate production, and major infrastructure projects requiring highvolume primary processing.
Limitations: Not designed for highly abrasive metallic ores or as a standalone solution for finished manufactured sand production without secondary stages.

3. CORE FEATURES

Direct Drive Crusher | Technical Basis: Eliminates hydraulic couplings and Vbelts | Operational Benefit: Direct power transmission increases fuel efficiency and reduces components prone to failure | ROI Impact: Field data shows up to 12% lower fuel consumption and 15% fewer drive system maintenance events annually.

Independent PreScreen Module | Technical Basis: Doubledeck vibrating grid mounted on a separate chassis leg | Operational Benefit: Removes up to 30% of fines before the crusher chamber, reducing wear on liners and preventing chamber packing | ROI Impact: Extends liner life by an average of 25%, decreasing part costs and changeout downtime.

Intelligent Process Control System | Technical Basis: PLCbased system with loadadaptive crusher settings and conveyor speeds | Operational Benefit: Automatically optimizes feed rate and crushing pressure based on material density, preventing overloads and ensuring consistent gradation | ROI Impact: Maintains target spec yield above 95%, minimizing waste and reprocessing.

Unified Service Access Platform | Technical Basis: 360degree walkways with centralized lubrication points and groundlevel access to major components | Operational Benefit: Your maintenance crew can perform daily checks, greasing, and visual inspections safely in under 20 minutes | ROI Impact: Reduces scheduled service time by an estimated 40%, increasing plant availability.

HeavyDuty Feeder & Hopper | Technical Basis: Reinforced hopper with apron feeder or vibrating grizzly feeder (VGF) options | Operational Benefit: Handles direct tipping from large wheel loaders (up to 10ton capacity), regulates feed to prevent crusher bridging | ROI Impact: Enables continuous operation at design capacity without feedrelated stoppages.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Mobile Primary Crushing Solution | Advantage (% improvement) |
| : | : | : | : |
| Crusher Liner Life (Abrasive Granite) | ~450 operating hours | 550600 operating hours | +22% to +33% |
| Total System Fuel Consumption (avg. t/h) | ~22 liters per hour @ 350 t/h | ~19.5 liters per hour @ 350 t/h| 11% |
| Mean Time Between Failure (MTBF) Drivetrain| ~1,200 hours| >1,500 hours| +25% |
| Setup Time from Transport to Production| 4560 minutes| <30 minutes| 50% |
| Target Product Consistency (Gradation Spec)| ±8% variance from target| ±4% variance from target| 50% tighter tolerance |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Up to 450 tonnes per hour (dependent on feed material).
Primary Crusher: Singletoggle jaw crusher; Feed opening options from 1m x .8m up to 1.2m x .9m.
Power Unit: Tier IV Final / Stage V compliant diesel engine; total installed power of approximately [XXX] kW.
OnBoard Screenbox: Tripledeck vibrating screen; screen area of [XX] m²; top deck mesh size configurable up to [XXX]mm.
Material Specifications: Hopper/feeder constructed from Hardox® steel; crusher jaws available in standard manganese or optional premium alloys for extended life.
Physical Dimensions (Operating): Length approx. [XX]m; Width approx. [XX]m; Height approx. [XX]m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system fitted as standard.

6. APPLICATION SCENARIOS

LargeScale Limestone Quarrying Operation

Challenge: A major aggregate producer faced frequent jaw liner changes every 6 weeks due to high silica content in limestone feed, causing over $[X] in annual downtime losses.
Solution: Implementation of our mobile primary plant with independent prescreen module removed fine abrasive particles before crushing.
Results: Liner life extended by over two weeks per cycle consistently—a net increase of over three cycles annually—reducing annual downtime by approximately [X] hours.

Major Highway Construction Project

Challenge: A contractor needed consistent Type II road base material across three different site locations but lacked budget for multiple static plants.
Solution: Deployment of a single trackmounted primary crushing unit that could be relocated between sites weekly without craneage due its quicksetup design.
Results: Achieved required production across all sites with one capital asset investment while maintaining gradation compliance above specification requirements throughout project duration.

Recycled Concrete Aggregate Production

Challenge: Processing demolition concrete resulted in excessive fines generation (<5mm), creating unsellable stockpiles that consumed valuable yard space without revenue generation potential
Solution:: Our mobile primary unit was configured with an aggressive prescreen deck specifically designed reject fines directly onto a separate stockpile before entering jaw chamber
Results:: Fines generation reduced by approximately thirty percent allowing more saleable product creation while simultaneously decreasing unnecessary wear within main crushing chamber

Commercial Considerations

Equipment pricing tiers are structured around core configuration:

• Tier I – Base Model – Standard jaw configuration with basic prescreen – Starting at approximately $[XXX],000 USD
• Tier II – HighCapacity Model – Larger jaw opening heavyduty feeder upgraded onboard screenbox – Starting at approximately $[XXX],000 USD
• Tier III – Customized Application Model – Specific alloy liners specialized screening media advanced automation packages – Priced upon application review

Optional features include:

• Magnet for ferrous metal removal
• Extended main product conveyor kits
• Advanced telemetry remote monitoring package
• Water spray dust suppression systems

Service packages available:

• Basic Warranty – twelve months parts labor excluding wear items
• Proactive Care Plan – includes scheduled inspections predictive maintenance support priority parts dispatch after warranty period expires cost determined based upon annual usage hours estimate provided during quotation process financing options available through our partner network include operating leases capital leases traditional loans terms typically range between thirtysix seventytwo months subject credit approval

FAQ

Q What type power supply required operate this mobile plant?
A The unit selfcontained dieselhydraulic power pack requires no external electrical connection making it suitable remote greenfield sites

Q Can this plant accept direct feed from large mining haul trucks?
A No this equipment designed receive feed via wheel loader excavator due height limitations apron feeder design For direct truck feeding consult our stationary plant division regarding larger grizzly feeder configurations

Q How does performance compare traditional stationary primary setup?
A While ultimate maximum tonnage may be lower than largest stationary plants our solution offers comparable performance most applications key advantages lie significantly lower mobilization costs operational flexibility rapid redeployment between sites

Q Are wear spare parts readily available globally?
A Yes we maintain standardized inventory critical wear parts across our distributor network three continents ensuring lead times typically under five business days most regions

Q What training provided operators maintenance staff?
A We provide comprehensive onsite commissioning training covering safe operation routine maintenance troubleshooting procedures Documentation includes detailed service manuals parts catalogs accessible via online portal