1. PAINPOINT DRIVEN OPENING

Are you managing a midtolarge scale aggregate operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant is a critical production asset, yet common operational challenges can significantly undermine its return on investment.

Inconsistent Feed & Downtime: Fluctuations in feed size and hardness lead to crusher stalls, unplanned downtime for clearing, and reduced average throughput far below the plant’s rated capacity.
High Operational & Maintenance Costs: Premature wear on liners and crusher components due to improper crushing chamber dynamics or inadequate material flow control results in excessive spare parts consumption and labor for changeouts.
Poor Product Shape & Gradation: Inefficient crushing stages produce excess flaky or elongated aggregates, reducing the percentage of premium, inspec product and limiting marketability for highvalue applications like concrete and asphalt.
Inefficient Plant Flow & Labor Intensity: Manual adjustments, poor transfer point design, and lack of integrated process control require constant operator intervention, leading to higher labor costs and variable product quality.

How do you ensure your 250300tph crushing plant delivers consistent, specontarget output while controlling wear costs and maximizing uptime? The solution lies in an engineered supply chain for a complete plant system designed from the ground up for reliability and efficiency.

2. PRODUCT OVERVIEW

This product describes a fully engineered supply chain for a stationary 250300 tonperhour (tph) hard rock stone crushing and screening plant. This is a complete circuit solution designed for highvolume production of aggregates for construction, road building, and railway ballast.

Operational Workflow:
1. Primary Crushing: Large quarryrun rock (up to 750mm) is reduced to <200mm by a robust primary jaw crusher.
2. Secondary & Tertiary Crushing: Material is then processed through a cone crusher (secondary) and optionally a further cone or impact crusher (tertiary) for precise size reduction and improved particle shape.
3. Material Screening: Multipledeck vibrating screens separate crushed material into precise specification fractions (e.g., 05mm, 510mm, 1020mm).
4. Material Handling & Stockpiling: A network of belt conveyors with adjustable discharge heights transports sized products to designated stockpiles.
5. Control & Monitoring: A centralized PLCbased control system allows operators to manage the entire flow from a single station.

Application Scope: Ideal for granite, basalt, limestone, and other abrasive aggregates. Suitable for large quarry operations dedicated to supplying readymix concrete plants, asphalt plants, and major infrastructure projects.

Limitations: This stationary plant solution requires foundational civil works and is designed for longterm operation at a fixed site. For fully mobile requirements on multiple shortduration sites, a mobile crushing plant configuration would be recommended.

3. CORE FEATURES

Intelligent Plant Control System | Technical Basis: Programmable Logic Controller (PLC) with humanmachine interface (HMI) | Operational Benefit: Enables singleoperator monitoring of the entire circuit flow rate motor loads screen performance | ROI Impact: Reduces labor requirements by up to 40% versus manual operation minimizes human errorinduced downtime

Laminated HeavyDuty Primary Crusher | Technical Basis: Deep symmetrical crushing chamber high manganese steel jaws with optimized nip angle | Operational Benefit: Handles maximum feed size efficiently reduces bridging risk provides consistent reduction ratio | ROI Impact: Extends jaw plate service life by an average of 25% lowering cost per ton crushed

LoadAdaptive Cone Crusher Technology | Technical Basis: Hydroset system or similar automatic setting regulation with overload protection | Operational Benefit: Automatically compensates for liner wear maintains product gradation protects crusher from tramp metal damage | ROI Impact: Maintains target throughput and product spec reduces unplanned stops by up to 30%

HighEfficiency MultiDeck Screening | Technical Basis: Heavyduty vibrating screens with adjustable throw angle polyurethane or wire mesh decks | Operational Benefit: Provides sharp accurate separation of up to four final product fractions increases screening efficiency to over 95% | ROI Impact: Maximizes yield of highvalue products minimizes recirculating load improving overall plant capacity

Engineered Conveyor System with Impact Zones | Technical Basis: Reinforced belt construction impact beds at loading points heavyduty idlers | Operational Benefit: Minimizes belt wear puncture spillage at critical transfer points ensures reliable material transport | ROI Impact: Reduces conveyor maintenance costs extends belt life lowers cleanup labor

Centralized Dust Suppression System | Technical Basis: Network of strategically placed nozzles connected to highpressure pumps water management system | Operational Benefit: Effectively controls dust at all major transfer points crusher discharges improving site environmental compliance operator safety | ROI Impact: Avoids regulatory fines reduces equipment wear from dust improves community relations

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | Our Engineered Supply Chain Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Availability| ~85% (planned + unplanned downtime) |>92% operational availability| +8% (+7+ more production days/year)|
| Crusher Liner Life| Varies widely often suboptimal| Guaranteed minimum based on rock abrasivity| Up to +25% longer life|
| Power Consumption per Ton| Fixed speed drives standard motors| Optimized drive packages energyefficient motors| 10% reduction in kWh/ton|
| Product Shape Index (Flakiness)| Often >15% without tertiary shaping|20% improvement producing more premium aggregate|
| Installation & Commissioning Time| 812 weeks typical field assembly|<6 weeks with modular preassembly| Up to 33% faster timetoproduction|

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 250 – 300 metric tons per hour (tph) of finished aggregate products.
Feed Material Maximum Size: Up to 750mm (quarryrun stone).
Primary Crusher: Jaw Crusher Model [e.g., JC5460], Feed Opening 1400x1100mm Power Requirement: 200 kW.
Secondary/Tertiary Crushers: Cone Crushers Model [e.g., HPC400], Power Requirement per unit: Up to 315 kW.
Screening Units: Tripledeck Vibrating Screens Size [e.g., 2400x6000mm] Power Requirement per unit: ~30 kW.
Total Installed Power: Approximately 800 – 1000 kW dependent on final configuration.
Key Material Specifications: Main frame structure ST37 steel Wear liners High manganese steel or chrome alloy Conveyor belting EP630/4 minimum.
Plant Footprint (LxW): Approximately ~80m x ~45m dependent on stockpile layout.
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature Dust emission control compliant with <50 mg/Nm³ standards Noise abatement measures available.

6. APPLICATION SCENARIOS

Highway Construction Project Supply Challenge Specific project required consistent supply of three graded aggregates (<20mm <10mm dust) over an18month period from highly abrasive basalt Solution Implementation of our tailored custom250300tph stone crushing plant featuring tertiary shaping circuit automated controls Results Plant achieved average output of280tph at96 availability Product shape index consistently below11 meeting strict DOT specifications Reduced wear part costs by18 versus previous project using older equipment

Large Commercial Quarry Expansion Challenge Existing aging400tph plant was unreliable Quarry needed scalable solution adding a new dedicated250300tph line without disrupting existing production Solution Supply installation commissioning of parallel circuit including primary jaw secondary tertiary cone crushers sharing existing feed system Results New line reached full300tph capacity within5 weeks of mechanical completion providing needed flexibility Overall site production increased by60 while maintenance teams focused on legacy equipment reliability

7. COMMERCIAL CONSIDERATIONS

Our supply chain provides clear pricing tiers based on scope:

1. Standard Design Package ($X.XM $X.XM): Includes core engineered plant design primary jaw secondary cone crushers basic screening conveyors electrical controls foundation drawings
2. Enhanced Performance Package ($X.XM $X.XM): Adds tertiary crushing stage advanced PLC automation upgraded dust suppression extended wear part warranties
3.
Optional features include hybrid diesel/electric power modules sound enclosures remote monitoring telematics systems automated lubrication systems

Service packages are offered separately:
Supervision Installation Commissioning
12/24/36month Extended Warranty Plans
Annual Inspection Maintenance Contracts

Financing options can be structured through partner institutions including operating lease capital lease or loan arrangements typically over37year terms subject to credit approval

FAQ

Q1 Is this custom250300tph stone crushing plant compatible with our existing primary feeding system or screens?
A1 The supply chain includes full engineering review Integration with existing upstream feeding hoppers or downstream screening units is possible provided interface specifications are shared early in the design phase Our engineering team will conduct compatibility analysis as part of the proposal process

Q2 What is the expected operational impact during installation commissioning?
A2 For greenfield sites impact is limited to your construction timeline For brownfield integration we develop a phased implementation plan minimizing interference with ongoing operations Field data shows typical tiein downtime can be contained within a72–96hour window when planned accordingly

Q3 How does this solution address longterm maintenance cost predictability?
A3 We provide detailed maintenance schedules lifecycle cost projections for major wear parts Based on supplied rock analysis guaranteed minimum tonnage figures for key consumables like mantles concaves jaw plates can be established offering greater budget certainty

Q4 What commercial terms are standard?
A4 Standard terms involve progress payments tied to key milestones factory acceptance shipping arrival site commissioning Final payment due upon successful performance test demonstrating sustained capacity over48hours Terms can vary based on project scope financing method selected optional packages included Payment security instruments are commonly used

Q5 What level of operator training is provided?
A5 Comprehensive training is included covering daily operation routine maintenance troubleshooting safety procedures Training occurs both during factory acceptance testing F.A.Tand onsite during commissioning We provide full digital manuals video libraries