1. PAINPOINT DRIVEN OPENING

Managing aggregate production costs requires precise control over your primary reduction and sizing stages. Inconsistent feed, unplanned maintenance, and inefficient material flow directly impact your bottom line. Are you facing these challenges?
High Operational Cost: Excessive fuel consumption from underutilized equipment and frequent component wear from improper crushing chamber dynamics.
Unscheduled Downtime: Premature failure of crusher liners, screens, and conveyors due to uncrushable material or overload events, halting your entire production line.
Inconsistent Product Yield: Inability to maintain precise product gradation due to fluctuating feed material or suboptimal screen efficiency, leading to product rejection or reprocessing.
Labor Intensity & Safety: Reliance on manual sorting, clearing of jammed material, and constant monitoring of multiple standalone units increases site risk and labor costs.

The right integrated crushing and screening equipment solution addresses these issues at the source. How do you transform raw feed into specification aggregate with maximum uptime and minimum cost per ton?

2. PRODUCT OVERVIEW: HIGHCAPACITY MODULAR CRUSHING & SCREENING PLANTS

This product category encompasses preengineered, stationary or semimobile processing systems that integrate primary jaw or impact crushers, secondary/tertiary cone crushers, multideck vibrating screens, and connecting conveyors into a single coordinated workflow.

Operational Workflow:
1. Primary Crushing & Scalping: Runofquarry material is fed into a robust primary crusher (e.g., jaw crusher) for initial size reduction. A dedicated scalping screen removes fines and bypasses subsize material to increase primary circuit efficiency.
2. Secondary/Tertiary Crushing: Partially crushed material is conveyed to secondary cone or impact crushers for further reduction. A closedcircuit loop with a screening unit allows for precise recirculation of oversize material.
3. Final Sizing & Stockpiling: Correctly sized material from the crushing stages is sent to final sizing screens where it is separated into multiple specification products (e.g., ¾” aggregate, ½” chips, manufactured sand) and conveyed to designated stockpiles.

Application Scope & Limitations:
Scope: Ideal for highvolume production of construction aggregates (limestone, granite, trap rock), recycled concrete/asphalt (RAP/RCA), and industrial minerals. Suited for both greenfield sites and plant upgrade projects requiring predictable output.
Limitations: Not designed for underground mining or extreme abrasive applications (e.g., taconite) without specific liner options. Maximum feed size is determined by the primary crusher opening; very sticky or highclay materials may require prewashing systems not included in standard configurations.

3. CORE FEATURES

Advanced Chamber Geometry | Technical Basis: Computermodeled kinematics and optimized nip angles | Operational Benefit: Creates a more aggressive crushing action with less slippage, increasing throughput by weight while reducing power draw per ton | ROI Impact: Higher yield from the same motor horsepower reduces energy costs by an estimated 812%.

PLCAutomated Process Control | Technical Basis: Centralized programmable logic controller with loadmanagement sensors and remote monitoring capability | Operational Benefit: Automatically regulates feeder speed, crusher setting adjustments based on chamber pressure, and conveyor sequencing to prevent overloads | ROI Impact: Minimizes operator errorrelated stoppages; field data shows a 1525% reduction in unplanned downtime events.

HeavyDuty Vibrating Screen with Side Tensioning | Technical Basis: High Gforce exciters combined with sideplate deck tensioning system | Operational Benefit: Maintains consistent screen cloth tension for superior material stratification and blinding resistance in wet/dry conditions | ROI Impact: Improves screening efficiency to 95%+, reducing recrush load and increasing saleable product yield.

Modular Walkway & Access Design | Technical Basis: ISOstandard guardrails, integrated service platforms, and centralized lubrication points | Operational Benefit: Your maintenance crews perform routine inspections, liner changes, and greasing safely and efficiently without specialized access equipment | ROI Impact: Cuts planned service time by up to 30%, enhancing overall plant availability.

Hybrid Power Flexibility | Technical Basis: Configurable power train accepting grid connection or onboard dieselelectric generation | Operational Benefit: Enables rapid deployment to remote sites without established power infrastructure while offering lowcost grid operation when available | ROI Impact: Provides operational flexibility; fuel consumption studies indicate a 40% savings versus traditional directdrive diesel setups when connected to grid power.

Integrated Metal Detection & AutoReverse | Technical Basis: Beltmounted tramp metal detector coupled with conveyor reverse sequence | Operational Benefit: Identifies ferrous contaminants (digger teeth, drill bits) before entering the primary crusher and automatically reverses the feed conveyor to eject the threat | ROI Impact Prevents catastrophic damage to crusher mantles/concaves; eliminates associated repair costs averaging tens of thousands per incident.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing And Screening Equipment Solution | Documented Advantage |
| : | : | : | : |
| Tons per Hour (TPH) per kW of Power | Varies by rock type; ~0.81.2 TPH/kW for hard granite circuit| Achieves 1.41.6 TPH/kW through optimized flow design & chamber geometry| +25% Efficiency |
| Liner Changeout Time (Primary Crusher) | 1824 hours with traditional manual methods| Completed in <10 hours via hydraulic assist tools & designed access| 55% Downtime |
| Screening Efficiency (5mm spec product)~90% under optimal conditions~95% sustained via sidetensioning decks & optimized throw|+5% Yield|
| Mean Time Between Failure (MTBF) Bearings~12 months in highvibration screen applications~18+ months using proprietary bearing isolation mounts|+50% Service Life|

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 to over 800 metric tons per hour (TPH), depending on model selection and feed material hardness (e.g., granite vs. limestone).
Power Requirements: Primary plant electrical demand ranges from 300 kVA to 800 kVA for full electric operation. Hybrid genset options available from 500 kVA.
Material Specifications: Crusher liners manufactured from Mn18% or Mn22% manganese steel with optional chromewhite iron alloys for highly abrasive applications. Structural frames use hightensile S355 steel.
Physical Dimensions (Typical ClosedCircuit Plant): Length: ~35m; Width: ~12m; Height (max): ~15m. Modular design allows transport in standard container sizes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C (4°F to 113°F). Dust suppression systems are rated for operation in environments with up to 80% relative humidity.

6. APPLICATION SCENARIOS

Aggregate Producer Hard Rock Quarry

Challenge: A granite quarry needed higher throughput but was constrained by grid power capacity at their remote site. Their existing plant suffered from low energy efficiency and frequent screen blinding.
Solution: Implementation of a hybridpowered modular crushing and screening plant featuring an energyefficient cone crusher with advanced chambers and sidetensioned screening decks.
Results: The plant achieved a 22% increase in tons per hour within the same power envelope while eliminating seasonal blinding issues on fine decks. Fuel costs dropped by 38% when operating on grid power during peak periods.

Recycling Contractor Urban C&D Processing

Challenge: Processing mixed construction & demolition debris led to excessive hidden metal contamination, causing severe damage approximately twice yearly at an average cost of $65k per incident in repairs and downtime.
Solution: Integration of a heavyduty metal detection system with autoreverse onto the primary feed conveyor of their new crushing train.
Results: Over an 18month period, the system detected and ejected over 42 pieces of tramp metal (>2kg). The capital investment was recovered within the first year by avoiding two major crushing chamber repair events.

7.COMMERCIAL CONSIDERATIONS

Our wholesale model provides competitive pricing tiers based on configuration complexity:
Tier I Base Stationary Plant: Includes primary crusher module,single secondary screen,and basic conveyors.Ideal for singleproduct operations.Pricing structured around core components.
Tier II ClosedCircuit Modular Plant: Complete multistage system with secondary/tertiary crushers,final sizing screens,and integrated walkways/guards.Most common configuration.Package pricing offers significant value versus piecemeal sourcing.
Tier III Custom HighCapacity System: Engineered solutions including automation controls,washing modules,and complex stockpiling conveyors.Priced on project scope with detailed quotation.

Optional features include dust encapsulation packages,wheeled mobility kits,coldclimate engine heaters,and advanced telemetry packages.Service packages range from basic commissioning support upto comprehensive annual maintenance contracts including liner program management.Financing options through our partners include operating leases,tailored rentaltoown structures,and project financing for qualifying entities.All equipment wholesaling operates under clearly defined MOQ terms which incentivize complete system purchases over individual component orders.Direct consultation provides specific figures based on your production goals.

8.FAQ

Q1:What is the typical lead time from order placementto commissioning?
A1 For standard Tier II modular plants lead time averages between16and20 weeks factoring manufacturing shippingand site preparationCustom Tier III solutions require detailed engineeringwith timelines established during project scoping

Q2 How does this equipment handle variationsin feed material sizeor hardness?
A2 The PLC control systemis programmedto monitorcrusher loadand can adjust feeder rates automaticallyFor significant changesin rock characteristicsadjustments tocrushereccentric speedor closedside settingare requiredwhich can be performed hydraulicallyfromthe groundlevel

Q3 Are these plants compatiblewith our existingconveyorsand stackers?
A3 Yesinterfacingwith existing downstreammaterial handlingequipmentis standard practiceOur engineeringteamwill reviewconnection points heightsand transfer chuterequirementsduringthe design phase

Q4 What trainingis providedfor our operationaland maintenance staff?
A4 Comprehensive trainingis included coveringdaily startup/shutdown proceduresroutine maintenancechecks safety protocolsand basic troubleshootingTraining occurs bothat our facilityduring factoryacceptancetesting(FAT)and onsite duringcommissioning

Q5 Can we sourcewear partsfrom local thirdparty suppliersor must we use OEM parts?
A5 Whilethe equipmentis designedto acceptgenericlinersin certainsizeswe strongly recommendgenuineOEM wear partsfor critical componentsThese partsare engineeredto matchthe exactkinematicsof the chamberensuringpublishedperformancemetricsandsafetyfactorsNonOEMpartsmay voidwarrantycoverageon relatedassemblies

Q6 What arethe key commercialterms regardingMOQ Minimum Order Quantity)?
A6 Our wholesale modelis structuredaround supplyingcomplete processing circuitsThe MOQ typicallyappliesto acorecrushingmodule(e g aprimaryjaw unitwith scalper)plusassociatedfeed/dischargeconveyorsThis approach ensuressystem compatibilityandperformanceContactour teamfor specificMOQ detailsbasedonyour targetcapacity

Q7 Whatisthe expectedservice lifeof themain structuralcomponents?
A7 The main chassis hoppersand nonwearingstructural elementshavea designlifeof aminimum25 yearsbasedon standardS355steelconstructionandcorrosionprotectionprotocolsprovidedthe equipmentis maintainedin accordancewith themanual