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 source of critical bottlenecks. Common challenges include:
High Maintenance Costs: Frequent bearing failures, screen cloth changes, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
Unscheduled Downtime: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Inefficient Material Flow: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
Inconsistent Product Gradation: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
Rising Energy Consumption: Older, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.

Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered crushing and screening equipment.

2. PRODUCT OVERVIEW

This content outlines the critical considerations for stationary and trackmounted crushing and screening equipment, the core machinery for reducing raw feed material (e.g., quarry rock, recycled concrete, mineral ore) into specified aggregate sizes. The operational workflow is a continuous process:
1. Primary Size Reduction: Large feed material is reduced by jaw or gyratory crushers.
2. Material Transport & Scalping: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. Secondary/Tertiary Crushing: Cone or impact crushers further reduce material to required dimensions.
4. Final Screening & Sorting: Multideck screens accurately separate crushed material into precise product fractions (e.g., ¾” chip, manufactured sand).
5. Stockpiling & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.

Application scope includes quarrying, mining, construction & demolition recycling, and aggregate production. Key limitations involve feed material abrasiveness (impacting wear life) and required final product specifications (dictating circuit design).

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Computermodeled kinematics and cavity profiles | Operational Benefit: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | ROI Impact: Up to 12% lower costperton in abrasive applications due to extended liner life.

Modular Screen Media System | Technical Basis: Quicktensioning wedgelock design with polyurethane damping | Operational Benefit: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | ROI Impact: Reduces labor hours for maintenance by ~70% per changeout, increasing plant availability.

Centralized Greasing & Condition Monitoring | Technical Basis: Automated lube points with flow sensors feeding a central PLC | Operational Benefit: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | ROI Impact: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.

Hybrid Power Drive System | Technical Basis: Dieselelectric configuration with onboard genset or external grid connection capability | Operational Benefit: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | ROI Impact: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.

HeavyDuty Feeder with PreScreening Section | Technical Basis: Grizzly feeder with integrated stepped grizzly bars or punch plate section | Operational Benefit: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | ROI Impact: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.

Reinforced Structural Frame Design | Technical Basis: Finite Element Analysis (FEA) optimized steel fabrication with highstress zone reinforcements | Operational Benefit: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | ROI Impact: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing & Screening Solution Documented Performance | Advantage (% Improvement) |
| : | : | : | : |
| Crusher Liner Wear Life (Abrasive Rock) | ~450,000 tons per set (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Longer Life |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (MTBF) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| Energy Consumption (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% Lower Energy Cost |
| Total Cost of Ownership (TCO) over 5 Years (Maintenance + Parts + Downtime)| Indexed at 100% for comparison| Estimated at 7882% of benchmark TCO| 18% to 22% Lower TCO |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Stationary plants from 150 to over 1,200 tonnes per hour (TPH). Trackmounted mobile units from 200 to 500 TPH.
Power Requirements: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 kVA depending on scale.
Material Specifications: Fabricated from S355JR structural steel; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Mn18Cr2/Mn22Cr2).
Physical Dimensions (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dustprotected bearings (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.

Urban C&D Recycling Operation

Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around capacity capability:
Tier I (600 TPH): Customengineered stationary crushing and screening plants.

Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems

Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits

Financing options are available including capital lease operating lease commercial loans tailored

8 FAQ

What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment

How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility

What is the typical lead time from order commissioning?
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months

Do you provide performance guarantees?
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation

What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard