1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable bottlenecks constraining your aggregate or mineral processing output? Inconsistent feed material, frequent maintenance stops, and inefficient material flow directly impact your plant's profitability and project timelines. Consider these common challenges:
Unscheduled Downtime: Component failures in critical crushers or screens halt entire production lines, costing thousands per hour in lost revenue and idle labor.
Inconsistent Product Gradation: Variable feed size and composition lead to offspec product, resulting in costly recrushing, wasted energy, and rejected loads.
High Operational Costs: Rising energy consumption, excessive wear part replacement cycles, and high manual labor requirements for clearing blockages erode profit margins.
Limited Plant Flexibility: Fixed configurations struggle to adapt to changing feedstock or final product requirements, forcing suboptimal operation or capitalintensive reconfiguration.

How do you achieve consistent throughput, reduce cost per ton, and improve overall plant availability? The integration of a purposeengineered export crushing and screening equipment processing plant provides a systematic solution.

2. PRODUCT OVERVIEW

A modern export crushing and screening equipment processing plant is a preengineered, modular processing system designed for the primary, secondary, and tertiary reduction of aggregates, ores, and industrial minerals. It integrates crushers, screens, conveyors, and control systems into a cohesive unit optimized for highvolume production.

Operational Workflow:
1. Primary Feeding & Scalping: Runofquarry or mine feed is introduced via a vibrating grizzly feeder, which removes fine material bypassing the primary crusher and scalps out oversize debris.
2. MultiStage Reduction: Material undergoes sequential size reduction in configured crushers (e.g., jaw → cone → impact) to achieve the target particle size distribution.
3. Classification & Sorting: Vibrating screens separate crushed material into precise product fractions (e.g., 05mm, 520mm, 2040mm).
4. Stockpiling & Recirculation: Onspec material is conveyed to designated stockpiles. Oversize material is automatically recirculated back into the crushing circuit for further processing.
5. Centralized Control: The entire process is managed from an automated control cabin for efficiency and safety.

Application Scope: Stationary or semimobile plants for quarrying, mining (nonmetallic), construction & demolition recycling, and largescale infrastructure projects.
Key Limitations: Not suitable for underground mining; maximum feed size and hardness are defined by the primary crusher specification; requires stable foundation preparation.

3. CORE FEATURES

Direct Drive Crusher Systems | Technical Basis: Elimination of Vbelts & sheaves | Operational Benefit: Reduced maintenance time by up to 30%, higher power transmission efficiency (up to 99%) | ROI Impact: Lower energy costs per ton crushed and reduced inventory of belt spares

PLCBased Intelligent Control System | Technical Basis: Centralized automation with load management algorithms | Operational Benefit: Optimizes crusher cavity levels & conveyor speeds automatically; prevents chokefeeding & reduces metaltometal wear | ROI Impact: Consistent throughput protection; extends manganese wear life by an average of 1520%

HeavyDuty Modular Chassis | Technical Basis: Unified structural frame with integrated walkways & access platforms | Operational Benefit: Simplifies shipping logistics; reduces onsite civil works; enhances operator safety during inspection | ROI Impact: Cuts installation time by up to 40% compared to piecepart assembly

Tier4 Final / EU Stage V DieselElectric Hybrid Power Option | Technical Basis: Diesel generator powers individual electric motors on each major component | Operational Benefit: Significant fuel savings versus direct diesel hydraulic drives; enables operation in remote gridless locations | ROI Impact: Field data shows up to 25% lower fuel consumption under typical load profiles

Advanced Dust Suppression & Noise Abatement Package | Technical Basis: Encapsulated transfer points with strategically placed spray nozzles & acoustic dampening panels | Operational Benefit: Maintains regulatory compliance for particulate matter (PM) and noise levels in sensitive regions | ROI Impact: Avoids costly site shutdowns due to environmental noncompliance

QuickRelease Wear Part Liners | Technical Basis: Hydraulicassisted locking mechanisms on jaw dies and cone mantles/concaves | Operational Benefit: Reduces liner changeout time from hours to minutes; minimizes exposure to manual handling risks | ROI Impact: Increases plant availability; lowers total labor cost associated with routine maintenance

MultiPort Screen Conveyor System | Technical Basis: Fines discharge conveyor integrated beneath multiple screen deck discharge points| Operational Benefit: Creates clean product separation without crosscontamination; allows for simultaneous production of multiple certified aggregates| ROI Impact: Maximizes saleable product yield from a single feed source

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Export Crushing & Screening Plant Solution | Documented Advantage |
| : | : | : | : |
| Tonnage Per Fuel Unit (T/m³) | Baseline (Direct Diesel Drive) | DieselElectric Hybrid Drive System| +25% Improvement |
| Mean Time Between Failure (MTBF) Critical Path| ~450 operating hours| ~600 operating hours| +33% Improvement |
| Installation & Commissioning Time (Weeks)| 46 weeks| 23 weeks| Up to 50% Reduction |
| Product Gradation Consistency (±% from spec)| ±10% variance common|< ±5% variance maintained| +50% More Precise |
Critical Path defined as primary crusher main bearings/liners & main screen box vibrators.

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 TPH to over 800 TPH final product output.
Primary Crusher Options: Jaw Crusher (1,200mm x 830mm feed opening) or Primary Impact Crusher (1,600mm rotor diameter).
Secondary/Tertiary Stage: Cone Crushers (up to 500kW) or Secondary Impact Crushers with hydraulic adjustment.
Screening Stage: Heavyduty inclined or horizontal vibrating screens up to 8' x 20' triple deck configuration.
Power Requirements: Plantwide electrical demand typically ranges from 750kVA to 1.5MVA. Optional selfcontained diesel generator sets from 500kVA to 2MVA.
Material Specifications: Highabrasion steel hoppers and chutes; AR400 liners at all highimpact transfer points; Screen decks available in woven wire or polyurethane modular panels.
Physical Dimensions (Typical Setup): Approximate footprint of 85m L x 35m W x 18m H. Designed in modular sections for standard containerized shipping.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust emission control achieves <10 mg/Nm³ at outlet with suppression system active.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project – Southeast Asia

Challenge: A large quarry needed to increase production of road base aggregates by over 60% but had limited space for plant expansion and faced stringent new dust emission regulations.
Solution: Implementation of a compact threestage export crushing plant featuring an encapsulated design with primary jaw crusher secondary/tertiary cone crushers in closed circuit with multideck screens
Results: Achieved target throughput of over650 TPH on a footprint30 smaller than the previous setup Particulate emissions were reduced by95 meeting new standards without additional retrofitting

C&D Recycling Operation – Middle East

Challenge: Processing highly variable construction demolition waste led frequent jamming secondary crushers inconsistent final product quality causing high rejection rates
Solution: Deployment hybrid diesel electric export screening plant featuring heavy duty grizzly feeder robust impact crusher advanced metal detection tramp iron relief system
Results: Plant availability increased85 through elimination uncrushable material jams Production high quality RCA Recycled Concrete Aggregate certified local road building standards achieving premium pricing

Portable Aggregates Production Infrastructure Project – Africa

Challenge Remote location no grid power required rapid deployment produce ballast railway project within months
Solution Semi mobile export processing plant equipped self contained power module quick setup chassis designed minimal concrete foundations
Results Full commissioning achieved weeks first load ballast produced days arrival site Equipment moved between three satellite quarry sites project timeline saving mobilization costs additional equipment rental

COMMERCIAL CONSIDERATIONS FOR EXPORT CRUSHING AND SCREENING EQUIPMENT PROCESSING PLANTS

Pricing is structured according capacity complexity:
Tier Basic Configuration High capacity jaw screen conveyor system ideal single product output Starting range $850000 $12M USD FOB
Tier Intermediate Configuration Two stage crushing closed circuit screening multiple products Starting range $18M $28M USD FOB
Tier Advanced Configuration Full three stage crushing multiple screen decks hybrid power advanced automation Starting range $35M+ USD FOB based final specification

Optional Features Upgrades:
Automated wear part monitoring systems Remote telematics performance tracking Additional dust suppression modules Winterization packages cold climate operations Extended capacity stacker conveyors stockpiling

Service Support Packages:
Standard Package Includes commissioning supervision operator training spare parts list
Premium Package Adds annual planned maintenance inspections priority parts dispatch discounted parts pricing first years operation
Platinum Package Comprehensive full coverage extended warranty including scheduled wear parts labor uptime guarantee subject terms conditions

Financing Options Available through partner institutions include capital lease operating lease lease purchase agreements tailored export credit agency ECA supported financing eligible markets

FREQUENTLY ASKED QUESTIONS FAQ EXPORT CRUSHING SCREENING EQUIPMENT PROCESSING PLANT

What level site preparation required before delivery?
Plant modules require compacted level substrate minimal concrete foundations anchor bolts Detailed foundation drawings issued advance facilitate parallel site preparation reduce downtime

How does plant handle variations feedstock hardness abrasiveness?
Crusher cavity profiles chamber options selectable onsite adjust CSS Closed Side Setting accommodate changes Wear part metallurgy specified based your specific material abrasion index silica content ensure economic service life

What typical lead time order placement commissioning?
For standard configurations lead time averages months ex works Custom engineered solutions may require months Detailed project schedule provided upon order confirmation including key milestones shipping dates installation phases

Are operators require specialized training run this equipment?
Comprehensive classroom practical training provided our commissioning engineers covering daily operation routine maintenance troubleshooting procedures Documentation includes full manuals schematics multilingual formats required Training conducted your site personnel ensure competency handover

What after sales support available internationally?
We maintain network authorized service partners key regions Additionally provide remote support via telematics systems direct video call assistance Critical spare parts stocked strategically located global hubs expedite shipping times minimize logistical delays