1. PAINPOINT DRIVEN OPENING

Are you managing a quarry operation where producing consistent, highquality railway ballast is compromising your bottom line? The challenges are specific and costly. Inconsistent particle shape and size distribution lead to high flakiness index aggregates, resulting in ballast rejection and wasted material. Frequent liner wear in crushing chambers increases maintenance downtime and consumable costs. Inefficient screening recirculation creates bottlenecks, limiting total plant throughput. Each hour of unplanned downtime represents significant lost revenue from both ballast production and your core aggregate products.

How do you increase ballast yield without sacrificing the quality specifications mandated by rail authorities? Can you reduce the total cost per ton for this critical product while maintaining system reliability? The solution lies in selecting purposeengineered quarry ballast crushing equipment designed to address these exact operational pressures.

2. PRODUCT OVERVIEW

This product line comprises heavyduty, secondary and tertiary crushing solutions specifically configured for highquality quarry ballast production. The typical operational workflow integrates seamlessly into an existing plant: (1) Primary crushed feed (typically 250mm) is conveyed to the ballast crusher; (2) Material undergoes progressive compression crushing within a specially configured chamber; (3) The crushed product is discharged onto a dedicated sizing screen; (4) Onspec material (+22mm/63mm, as per local standards) is sent to stockpile, while oversize is recirculated; (5) Undersize is redirected for production of other aggregate grades.

Application scope includes dedicated ballast production lines within hard rock quarries (granite, basalt, limestone). Key limitations involve feed size compatibility with primary crusher discharge and the requirement for a closedcircuit system with accurate screening for optimal yield.

3. CORE FEATURES

Advanced Chamber Geometry | Technical Basis: Multizone crushing profile with optimized nip angles | Operational Benefit: Promotes interparticle crushing, producing superior cubical product with low flakiness index (<15% typical) | ROI Impact: Increases saleable ballast yield by 815%, reducing waste and maximizing revenue from each ton of raw feed.

Hydroset CSS Adjustment | Technical Basis: Hydraulic piston for closedside setting adjustment under load | Operational Benefit: Operators can finetune product gradation in minutes without stopping production, responding to changes in feed characteristics. | ROI Impact: Minimizes adjustment downtime by up to 90% compared to manual shim systems, ensuring consistent spec output.

HeavyDuty Rotor & Bearings | Technical Basis: Forged alloy steel rotor supported by oversized spherical roller bearings | Operational Benefit: Sustains high inertia for efficient crushing of hard abrasive rock with minimal vibration. | ROI Impact: Extends major component service life, reducing risk of catastrophic failure and associated repair costs and extended downtime.

Liner Material Options | Technical Basis: Selection of manganese steel grades and composite alloys based on rock abrasiveness | Operational Benefit: Provides optimal wear life versus cost balance for specific mineralogy. | ROI Impact: Reduces costperton for wear liners by 2040% through targeted material selection and extended changeout intervals.

Integrated Automation Interface | Technical Basis: PLCcompatible sensors for CSS, power draw, and bearing temperature monitoring | Operational Benefit: Enables realtime performance tracking and predictive maintenance alerts, integrating with plantwide control systems. | ROI Impact: Prevents unplanned stops through condition monitoring and allows datadriven optimization of throughput versus power consumption.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Quarry Ballast Crushing Solution | Advantage (% improvement) |
| : | : | : | : |
| Ballast Product Yield (inspec material) | 6575% of crusher output stream| 7885% of crusher output stream| +10% average |
| Liner Wear Life (in abrasive granite) | 450,000 550,000 tons| 600,000 750,000 tons| +25% average |
| Availability (scheduled & unscheduled) | 9294%| 9698%| +4 percentage points |
| Specific Power Consumption (kWh/ton)| Varies widely by design| Optimized chamber design reduces recirculating load| Up to 12% |
| Gradation Consistency (maintaining spec)| Requires frequent manual CSS checks| Hydroset automation allows continuous control| Deviation reduced by ~60% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 to over 1,200 metric tons per hour of finished ballast product.
Power Requirements: Drive motor from 200 kW up to 600 kW, compatible with standard highvoltage quarry supply.
Material Specifications: Engineered for compressive strength >150 MPa abrasive rock. Standard wear liners are ASMT A128 Grade B3/B4 manganese steel.
Physical Dimensions: Typical footprint ranges from ~6m x 4m for midrange models. Total installed weight from 25t to 70t.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust sealing systems are rated for continuous outdoor operation.

6. APPLICATION SCENARIOS

Regional Rail Network Expansion Project

Challenge: A contractor needed guaranteed supply of Class I railway ballast meeting stringent national rail specs (PSD & FI). Their existing cone crusher produced excessive fines and flaky material.
Solution: Implementation of a tertiarystage quarry ballast crushing equipment configured with a cubical chamber profile and paired with a highcapacity horizontal screen.
Results: Ballast yield improved from 68% to 82%. Product consistently passed all quality audits, enabling the contractor to secure a premium supply agreement.

Granite Quarry Diversifying into Rail Supply

Challenge: A quarry producing road aggregates sought to enter the rail ballast market but faced high wear costs and poor shape when processing their very abrasive granite.
Solution: Installation of a dedicated ballast crushing circuit featuring our solution with optional XT alloy liners designed for highabrasion applications.
Results: Liner life increased by 32%, making ballast production economically viable. The quarry successfully diversified its revenue streams within the same rock reserve.

7. COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around machine capacity and optional features:
Standard Tier: Highefficiency base model for standard hard rock applications.
Performance Tier: Includes automation package (Hydroset+), advanced monitoring sensors, and premium baseline liners.
Custom Tier: Customized wear package metallurgy or specific motor configurations for unique site conditions.

Key optional features include automated lubrication systems, spillage conveyor packages, and advanced vibration monitoring telemetry.

Service packages range from basic commissioning support to comprehensive multiyear maintenance agreements covering planned inspections, liner changeout labor support, and priority parts dispatch.

Financing options include traditional capital equipment loans as well as productivitybased leasing structures that align payments with operational tonnage targets.

8. FAQ

1. Is this equipment compatible with our existing primary jaw crusher and screening plant?
Yes. Our engineering team will review your primary crusher's discharge gradation and your screen box configurations to ensure seamless integration and optimize closedcircuit flow rates.

2. What is the expected impact on our overall plant electrical load?
Field data shows that due to higher efficiency in particle breakage and reduced recirculating load on screens overall circuit energy use per ton of finished ballast often decreases despite the addition of a dedicated crusher.

3. How does the maintenance schedule compare to other conetype crushers?
With common access points standardized service intervals remain similar however key component lives particularly bearings are extended reducing the frequency of major interventions lowering total lifetime service hours

4. Can you guarantee final product gradation will meet our country's railway specifications?
While final product depends on feed characteristics screen configuration we provide performance modeling based on your rock test data We guarantee the mechanical performance of the equipment itself

5. What are typical delivery lead times?
For standard models lead times range from months depending on current manufacturing capacity Custom configurations may require additional time

6. Are training programs provided for our operations maintenance staff
Comprehensive onsite training during commissioning is included covering safe operation routine maintenance procedures troubleshooting guidelines

7 What warranty terms apply
We offer month warranty on all parts against manufacturing defects Extended warranty coverage is available through our service package agreements