1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, traditional crushing and screening setups often present persistent challenges: inconsistent final product gradation leading to rejected loads, excessive wear part consumption due to inefficient chamber designs, and high labor costs from manual adjustments and blockages. These issues directly impact your bottom line through wasted material, unscheduled maintenance, and lost production hours.

How can you achieve consistent, inspec aggregate output while controlling operational expenditure? Is there a way to reduce unplanned downtime and extend service intervals without compromising throughput? The solution lies in specifying equipment engineered not just for peak performance, but for predictable, costeffective operation across its lifecycle.

2. PRODUCT OVERVIEW

This product line encompasses a comprehensive range of stationary and trackmounted export crushing and screening equipment designed for private label manufacturing partners. The operational workflow is engineered for linear efficiency: (1) Primary feeding and size reduction via jaw or impact crushers, (2) Intermediate sizing and stockpiling with cone crushers and screens, (3) Final precision screening for product separation, (4) Recirculation of oversize material, and (5) Integrated conveying for seamless material flow.

This equipment is applicable for medium to largescale aggregate production, C&D recycling, and nonabrasive mineral processing. It is optimally designed for processed natural stone and recycled concrete; limitations exist for highly abrasive or chemically aggressive materials without specific liner configurations.

3. CORE FEATURES

Hydroset CSS Adjustment | Technical Basis: Hydraulic piston supporting the main shaft | Operational Benefit: Closedside setting (CSS) adjustments can be made in under 60 seconds under load, enabling rapid product size changes. | ROI Impact: Reduces nonproductive time by up to 80% compared to manual shim systems, increasing plant flexibility.

Modular Liner Retention System | Technical Basis: Mechanically locked liner segments with wedge bolts | Operational Benefit: Eliminates backing compound use, reduces liner changeout time by an average of 40%. | ROI Impact: Lowers labor costs per maintenance event and increases crusher availability.

Tier 4 Final / Stage V Compliant Power Unit | Technical Basis: Advanced diesel engine with integrated SCR/DPF technology | Operational Benefit: Provides full power while meeting global emissions standards without derating. | ROI Impact: Ensures regulatory compliance for export markets and avoids potential site operating restrictions.

Independent PreScreen & ByPass Conveyor | Technical Basis: Dedicated vibrating grid before the crusher inlet with a direct fines conveyor | Operational Benefit: Removes natural fines from the feed stream, reducing crusher chamber volume consumption and wear. | ROI Impact: Increases effective throughput of valuable material by up to 30% and extends wear part life.

PLCBased Plant Control System | Technical Basis: Centralized programmable logic controller with touchscreen HMI | Operational Benefit: Allows singlepoint monitoring of all plant functions, feed rates, and diagnostics. Enables automated startup sequences. | ROI Impact: Minimizes operator error, optimizes power consumption per ton crushed, and provides actionable data for preventative maintenance scheduling.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Export Crushing & Screening Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner ChangeOut Time (Primary Crusher) | 1624 hours (crew of 3) | 812 hours (crew of 3) | ~50% faster |
| Fuel Consumption per Ton Crushed| 0.8 1.2 liters/tonne| 0.65 0.9 liters/tonne| ~20% more efficient |
| Screening Efficiency (Middeck) | ~85% material separation| ~92% material separation| ~8% improvement |
| Mean Time Between Failures (Hydraulic System)| ~2,000 hours| ~3,200 hours| ~60% longer |

_(Based on field data from comparable installations processing granite/C&D waste.)_

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 to 600 tonnes per hour for hard rock applications.
Power Requirements: Primary plant options from 250 kVA to 800 kVA electrical; Trackmounted units feature diesel engines from 300 kW to 450 kW.
Material Specifications: Highstrength steel chassis; Crusher jaws/mantles in standard Mn14%18% or optional chrome iron alloys; Screen decks in hightensile woven wire or polyurethane panels.
Physical Dimensions (Example Primary + Screening Plant): Approximate footprint of 32m L x 18m W x 12m H. Trackmounted units comply with standard transport width regulations.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C. Dust suppression system rated at ≤50mg/Nm³ emission control.

6. APPLICATION SCENARIOS

Aggregate Quarry Expansion in Southeast Asia

Challenge: A quarry operator needed to increase production of three certified aggregate products but faced space constraints preventing a traditional fixed plant expansion.
Solution: Implementation of a multistage trackmounted export crushing and screening equipment setup featuring a primary jaw crusher with independent prescreen, secondary cone crusher, and tripledeck finishing screen.
Results: Achieved required production increase of over 35% within the existing site footprint within one week of commissioning; reduced offspec product by approximately 15%.

Urban C&D Recycling Operation in Europe

Challenge: High contamination rates in feed material caused frequent blockages in secondary crushers and inconsistent final recycled aggregate quality.
Solution: Integration of a heavyduty scalping screen ahead of the primary crusher circuit within their new private label crushing system.
Results: Reduced unscheduled downtime due to blockages by an estimated 70%, producing a cleaner final product that commanded a higher market price per ton.

7. COMMERCIAL CONSIDERATIONS

Equipment is offered across three primary tiers:
1. Standard Duty: For consistent feed materials like limestone; includes core features with standard wear parts.
2. Heavy Duty: For mixed or abrasive feeds like granite/C&D; includes upgraded liners, heavierduty bearings/belts.
3. Modular SkidMounted: Preassembled modules for rapid deployment on concrete foundations.

Optional features include advanced dust suppression cannons,
metal detection systems,
and remote telemetry packages.
Service packages range from basic commissioning support
to comprehensive annual maintenance contracts
with guaranteed parts availability SLAs.
Financing options are structured through partner institutions,
offering operating lease or capital purchase plans
tailored to project cash flow requirements.

8.FAQ

Q1: Is this equipment compatible with our existing conveyors or screens?
A1: Yes.The modular design allows integration into existing circuits.Critical interface points such as discharge heights,belt widths,and control system protocols are finalized during the engineering phase prior to manufacturing.

Q2:What is the expected operational impact on our current workforce?
A2:The automation features reduce manual intervention,but training is provided.The centralized PLC control system typically requires fewer operators for monitoring,but shifts their role towards process optimization rather than manual adjustment.Field data indicates a training period of one week is standard for operators familiar with similar machinery

Q3:What are typical lead times,and what commercial terms are offered?
A3 Lead times vary by configuration,ranging from 12 weeks for standard designs 24 weeks+for fully custom plants.Commercial terms typically involve progress payments tied to key manufacturing milestones,FOB origin Incoterms are standard

Q4 How do you ensure spare parts availability under a private label agreement?
A4 We maintain consignment stock programs at regional logistics hubs based on forecasted demand.Partner portals provide realtime parts inventory visibility,and critical component kits are specified at pointoforder

Q5 What site preparation is required prior commissioning?
A5 A detailed site preparation document is supplied.General requirements include level compacted ground adequate crane access provision utilities water electricity fuel drainage The foundation design drawings are provided as part technical documentation