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 persistent issues:
Excessive Downtime for Maintenance: Frequent liner changes, bearing failures, and component wear halt your entire processing line. Every hour of stoppage can represent thousands in lost production.
Inconsistent Product Gradation: Fluctuations in feed material lead to offspec product, resulting in costly recrushing cycles, rejected loads, and dissatisfied customers.
High Energy Consumption: Older or inefficient drive systems and poorly optimized material flow lead to unsustainable power costs, a primary operational expense.
Rapid Wear Part Degradation: Abrasive materials prematurely destroy crusher liners, screen decks, and conveyor components, driving up your costperton processed.
Limited Plant Flexibility: Fixed configurations struggle to adapt to changing feed stock or final product requirements, forcing suboptimal operation or capital investment in additional equipment.

Is your current crushing and screening equipment a source of variable cost and constant concern? What would a 1520% reduction in your costperton mean for your annual profitability?

2. PRODUCT OVERVIEW: HEAVYDUTY MODULAR CRUSHING AND SCREENING PLANTS

This product line encompasses a range of preengineered, heavyduty modular crushing and screening plants designed for highvolume aggregate production and mineral processing. The operational workflow is engineered for continuous material flow:

1. Primary Feeding & Crushing: Dumpfed or loaderfed primary crusher (jaw or gyratory) reduces runofquarry rock to a conveyable size.
2. Primary Screening & Conveying: A robust screen separates sized material from oversize, which is recirculated, while onspec product is conveyed to stockpile or secondary circuits.
3. Secondary/Tertiary Crushing: Cone crushers or impactors further reduce material in closedcircuit with screens to achieve precise final gradations.
4. Final Screening & Stockpiling: Multipledeck screens sort finished products into designated grades (e.g., base course, chips, sand) via radial stackers.

Application Scope: Ideal for stationary quarries, largescale mining operations, and major infrastructure projects requiring consistent output of 300 1,500+ tons per hour of crushed aggregate.

Key Limitations: These are largescale installations requiring significant site preparation and capital investment. They are not designed for smallscale or highly mobile contract crushing applications without substantial setup time.

3. CORE FEATURES

Advanced Chamber Geometry | Technical Basis: Optimized kinematics and cavity profile | Operational Benefit: Delivers a consistent crushing action that maintains product shape specification and reduces crusher bottlenecking | ROI Impact: Field data shows up to 12% higher throughput with improved particle shape index.

Hydraulic Setting Adjustment (HSA) System | Technical Basis: Remoteadjustable crusher discharge setting via hydraulic rams | Operational Benefit: Allows operators to change product size or compensate for wear in under 5 minutes without stopping the crusher | ROI Impact: Eliminates manual shim adjustments, reducing downtime for CSS changes by over 90%.

Modular Frame Construction | Technical Basis: Bolttogether, hightensile steel sections with precision machining | Operational Benefit: Enables faster onsite assembly with standard tools, reduces foundation requirements, and allows future plant reconfiguration | ROI Impact: Cuts installation time by an estimated 30%, accelerating timetorevenue.

Centralized Greasing & Lube System | Technical Basis: Automated singlepoint lubrication circuits for all major bearings | Operational Benefit: Ensures correct lubrication intervals and volumes are maintained consistently by operators | ROI Impact: Industry testing demonstrates a direct correlation with a 2540% increase in bearing service life under abrasive conditions.

HighStrength Screen Media & Tensioning System | Technical Basis: Interlocked polyurethane or hybrid rubber/steel panels with uniform tensioning rails | Operational Benefit: Minimizes blinding and pegging while dramatically increasing panel longevity compared to woven wire | ROI Impact: Reduces screen media changeout frequency by 3x5x, lowering parts inventory costs and maintenance labor hours.

PLCBased Plant Automation System | Technical Basis: Programmable Logic Controller managing startup sequences, interlocks, load management, and fault diagnostics | Operational Benefit: Provides operators with clear system status alerts and prevents cascading equipment damage from faults like tramp metal or feeder blockages | ROI Impact: Protects major component investments; typical payback period is under 18 months through avoided repair events.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing And Screening Plant Solution | Documented Advantage |
| : | : | : | : |
| Availability (Uptime) | 8588% (scheduled & unscheduled) |>92% availability over first three years| +57% improvement |
| CostPerTon (Wear Parts) | $0.85 $1.10 / ton processed | $0.65 $0.80 / ton processed | ~20% reduction |
| Specific Energy Consumption | 0.8 1.1 kWh / ton |0.65 0.75 kWh / ton | Up to 23% improvement |
| Screen Panel Lifespan (Abrasive Granite) |400 600 hours |1800 2200 hours |300%+ improvement |
| OnSite Assembly Time (300 tph plant) |1418 days |1012 days |<30% faster |

5.TECHNICAL SPECIFICATIONS

Nominal Capacity Range: Configurable from 300 to over 1,500 metric tons per hour (TPH), depending on feed material hardness (Wi) and final product size.
Primary Crusher Options: Jaw Crusher (1,200mm x 830mm feed opening) or Primary Gyratory Crusher (54” model). Power rating from 200 kW to 375 kW.
Secondary/Tertiary Crushers: HeavyDuty Cone Crushers with multiple chamber options. Power rating from 160 kW to 315 kW.
Screen Decks: Tripledeck inclined vibrating screens; sizes from2 .4m x6 mto3 .0mx9 .0m.Drive power up to30 kW.
Material Specifications: Main frame fabrications from S355JR structural steel; wear liners available in AR400/500 steel,manganese steel,and applicationspecific alloys.
Physical Dimensions (Modular Units): Individual modules designed for standard heavy transport.Max height4 .2m,max width3 .5m.Length varies by function(815m).
Environmental Operating Range: Designed for ambient temperatures from 25°Cto+45°C.Electrical enclosures ratedtoIP65.Dust suppression system integration points standard.

6\. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge:A major quarry neededtoincrease productionby40%tofulfill anew highway contract but faced space constraintsandpermitted noise/dust limits.The existing plant couldnotbeexpanded easily.Solution:A new modularcrushingandscreeningplantwas installedadjacenttotheexisting pit.Allprimarycrushingwas relocated,andthecircuit was designedwithfullyenclosedtransfer pointsandhighefficiencyfilters.R esults:Theplant achievedits target throughputof850TPHwithin oneweekofcommissioning.Dust emissions remainedwithin strict newregulations,andthe modular design allowedthe secondarysectiontobe repositionedwhen the pit advanced,savingfuturecapital.

Recycled Concrete&Aggregate(RCA)Processing

Challenge:A demolition contractorlandfilledover30%ofprocessedmaterialasunsalable finesandexperienced rapidwearin their existing impactor.Solution:A specializedcrushingandscreeningplant featuringanimpactcrusherwithgrinding pathrotoranda highfrequency rinsingscreenwas deployed.The circuit includedamagnetic separatorforferrous removal.R esults:The plant increasedsalableproduct yieldfrom70%to92%.The specificwearpart designforabrasive concreteextendedliner lifefrom250hourstoapproximately600hours.Rinsingscreensproducedaclean,+¾”aggregate thatcommandedapremium pricein themarketplace.

7\. COMMERCIAL CONSIDERATIONS

Ourcrushingandscreeningequipmentis offeredin tieredconfigurationsbasedoncapacityandcomplexity:

Base Plant Tier(300600TPH):Includesprimarycrushermodule,screenmodule,andbasic conveyors.Idealfor singleproductfocus.Pricing structuredforrapidROIonstandardmaterials.
Advanced Plant Tier(6001200TPH):Addssecondarycrushingcircuitin closedloop,withmultiplefinalproduct screensandPLCautomation.Optionalfeaturesinclude automatedsettingregulation(ASRi)andcrusher telemetry.
Custom Process Tier(1200TPH+):Fullyengineeredsystemsincorporatingtertiary crushing,washing,sandclassification,andadvancedplantwidecontrolsystems.Optionalfeaturesare quotedprojectspecifically.

Service packagesrangefrombasicwarranty supporttocomprehensivePerformanceContractscoveringwearpartsatafixedcostperton.Financingoptionsincludeoperational leases,tailoredrentaltoownprograms,andprojectfinancingsolutionsforqualified buyers.Equipment pricingis projectspecific;requestadetailedproposalbasedonyourfeedanalysisandproductiontargets.

8\. FAQ

Q:What levelofsite preparationis requiredforyourmodularplants?
A:Themodulesrequireacompactedlevelgravelpadorfoundationpiersas perourcivil drawings.Powerconnectionpoints,dustwater supply,andadequateaccessfortransportandservicemustbeprovided.We supplydetailed site requirementdocumentationwithany proposal.

Q:Canyourplantsintegratewithourexistingequipmentlikeprimarycrushersorstackers?
A Yes.Interfacingwithequipmentfromothermanufacturersis common.Weengineercompatibletransferchutes,beltconveyorconnections,andcontrolsysteminterfaces(typicallyviahardwireI/O)tocreateacohesivecircuit.Electricalvoltageandcontrolprotocolsmustbeconfirmedduringdesign

Q Howdoestheautomationsystemimproveoperator safetyandreliability?
A ThePLCmanagessequentialstartup/shutdownpreventingequipmentfromstartingoutoforder.ItmonitorsmotorloadsbearingtemperaturesvibrationlevelsIfaparameterexceedsasetlimititcaninitiateacontrolledshutdownoralertoperatorspreventingcatastrophicfailure

Q Whatisthetypicalleadtimefromorderto commissioning?
A Forstandardconfigurationsleadtimeis approximately20–24weeksCustomengineeredsolutionsmayrequire28–32weeksTimelinesarecontingenton timelyapprovalsofsitedrawingsandelectricaldetails

Q Arewearpartsguaranteedtobeavailableforthelifeoftheequipment?
A We maintainaninventoryofcriticalwearpartsatregionalservicecentersanda commitmenttomaintainpatternsfortheminimumservice lifeofthemachineasdefinedin oursalesagreementTypicallythis isa15yearcommitment

Q Do youofferoperator trainingas part ofthe purchase?
A Yes.Acomprehensive trainingprogramforbothoperatorsandmaintenancetechniciansis includedwithcommissioningWe provideclassroominstructiononsystemprinciplesfollowedbyhandson trainingatthe installedplantlocationManualsareprovidedindigitalformat

Q Canwefinancetheequipmentthroughyourofferingoperationalleasepayments?
A Severalcommercialoptionsareavailableincludingcapitalleasesoperationalleases(runrateexpense)andinstallmentpurchaseplansOurfinance teamcanprovideatermsheetbasedonyourcompanysfinancialprofile