1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable bottlenecks eroding your project margins? For plant managers and contractors, inefficient bulk material processing directly impacts profitability. Common challenges include:

Excessive Downtime: Unplanned maintenance and component failures in critical crushing and screening stages halt entire production lines, costing thousands per hour in lost output and labor.
Inconsistent Product Quality: Variable feed material leads to offspec aggregate sizes, resulting in product rejection, rework, and diminished customer trust.
High Operational Costs: Rising energy consumption from inefficient drives, frequent wear part replacement, and the labor intensity of manual adjustments steadily increase your costperton.
Scalability Limitations: Fixedconfiguration plants struggle to adapt to changing project demands or new material specifications, forcing capitalintensive overhauls or suboptimal operation.

Is your current equipment portfolio equipped to deliver the throughput consistency and cost control required in today’s competitive market? The solution lies in specifying machinery engineered not just for capacity, but for total operational efficiency.

2. PRODUCT OVERVIEW: HEAVYDUTY CRUSHING AND SCREENING EQUIPMENT

This product line encompasses a coordinated fleet of primary crushers, secondary/tertiary crushers, and multideck screening plants designed for the continuous processing of bulk aggregates, mined ore, and recycled materials. The operational workflow is engineered for minimal intervention:

1. Primary Reduction: ROM (RunofMine) or quarryrun material is fed into a robust primary jaw or gyratory crusher for initial size reduction.
2. PreScreening & Sorting: Material is conveyed to a primary screen where undersize is diverted to bypass unnecessary crushing stages, improving efficiency.
3. Secondary/Tertiary Crushing: Oversize material is routed through cone or impact crushers for precise reduction to target product dimensions.
4. Final Product Screening: Crushed material is classified on secondary screens into precise specification fractions (e.g., ¾” aggregate, manufactured sand).
5. Stockpiling & ReCirculation: Onspec material is conveyed to stockpiles; oversize is automatically recirculated back into the circuit.

Application Scope: Ideal for highvolume aggregate production (limestone, granite), base preparation for largescale civil works, and mineral processing prebeneficiation. Limitations: Not suitable for ultrafine grinding (sub5mm) requiring specialized milling circuits or for processing highly abrasive materials without specific liner configurations.

3. CORE FEATURES

Advanced Chamber Geometry | Technical Basis: Optimized nip angles and crushing cavity profiles | Operational Benefit: Increases firstpass yield of specification product by up to 15%, reducing recirculating load | ROI Impact: Lower energy use per ton and reduced wear on downstream components

Hybrid Power Drive System | Technical Basis: Direct hydraulic drive coupled with variable frequency electric motors | Operational Benefit: Provides peak torque for tramp metal events while maintaining optimal energy efficiency during normal operation | ROI Impact: Field data shows a 1218% reduction in power consumption compared to traditional direct diesel drives

Modular Wear Component System | Technical Basis: Standardized, reversible liners and segmented wear parts | Operational Benefit: Reduces changeout time by up to 40% using common tools; extends service intervals through even wear utilization | ROI Impact: Lowers inventory costs and minimizes downtime labor expenses

Intelligent Process Automation (IPA) | Technical Basis: PLCcontrolled setting adjustment based on realtime feed analysis and power draw monitoring | Operational Benefit: Maintains consistent product gradation automatically; alerts operators to developing issues before failure | ROI Impact: Reduces product variability waste by an average of 8% and prevents catastrophic damage events

Centralized Greasing & Lube Circuit | Technical Basis: Automated, programmable lubrication system with blockage detection | Operational Benefit: Ensures critical bearings receive correct lubrication without manual intervention; provides early warning of contamination | ROI Impact: Extends bearing service life by approximately 30%, avoiding unplanned stoppages

QuickRelease Conveyor Systems | Technical Basis: Pinandhinge design with hydraulic tensioners for head and tail sections | Operational Benefit: Enables rapid reconfiguration of plant layout or belt replacement in under two hours | ROI Impact: Enhances plant flexibility for different project phases with minimal downtime

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing & Screening Solution Documented Advantage |
| : | : | : |
| Tons per Hour (TPH) Sustained Throughput| Fluctuates ±10% with feed variation| Maintains within ±3% via automated crusher control| +7% more consistent output|
| Wear Part Cost per 10k Tons Processed| Based on standard manganese steel liners| Utilizes proprietary alloy matrix liners| 22% lower consumable cost|
| Mean Time Between Failure (MTBF) – Drivetrain| ~1,200 operating hours| Exceeds 1,800 operating hours (verified)| +50% improvement in reliability|
| OnSpec Product Yield Percentage| Typically 8590% depending on material| Consistently achieves 9295% yield range| +5 percentage point increase|
| Full Plant Reconfiguration Time (Modular)| 35 working days with crane support| Achieved in 12 days using integrated systems| ~60% faster redeployment|

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Configurations from 300 TPH to 1,200+ TPH stationary plants; mobile trackmounted units from 150 to 500 TPH.
Power Requirements: Primary crusher drives from 150 kW to 450 kW; total plant connected load typically between 600 kW 1.8 MW depending on configuration. Options for dualpower (diesel/electric) mobile units.
Material Specifications: Fabricated from hightensile steel (min. yield strength 350 MPa); Crusher jaws/liners available in multiple grades including T400 & T500 manganese steel or optional chromium carbide overlays for highly abrasive applications.
Physical Dimensions (Sample Mobile Jaw Plant): Operating Length: ~19m; Width: ~3.5m; Height: ~4.2m; Transport Weight: ~62 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dust suppression systems standard; sound enclosures available to reduce operating dB below local compliance levels.

6. APPLICATION SCENARIOS

Aggregate Quarry Expansion | Challenge: A granite quarry needed to increase output by 35% without expanding its physical footprint or significantly adding crew. Existing equipment produced excessive fines and suffered frequent liner wear failures.| Solution: Implementation of a tertiary cone crusher with our Advanced Chamber Geometry and IPA automation system was integrated into the existing circuit.| Results: Achieved a 38% throughput increase within the same footprint. Onspec chip production rose by 11%, while liner life extended by two operational weeks per set.

Major Infrastructure Project – Base Course Production | Challenge: A contractor for a highway project faced strict gradation specifications with penalties for noncompliance. Their mobile plant required constant manual adjustment leading to inconsistency.| Solution Deployment of a closedcircuit impact crusher and screen plant featuring the Hybrid Power Drive and Modular Wear Component System.| Results Product consistency met specification bands 99% of the time, avoiding penalties.The fuel efficiency gain yielded an estimated $18,000 savings over the project’s duration.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Equipment is offered across three valueengineered tiers:
Standard Duty: For consistent, nonabrasive materials (e.g., limestone). Focuses on core reliability.
Heavy Duty (Most Common): Includes features like hybrid drives and modular wear systems for mixed/variable feed materials.
Extreme Duty: Incorporates premium liner options, enhanced automation packages,and heavyduty structures for maximum abrasion resistanceand uptime.

Optional Features & Packages: Remote monitoring telematics package; advanced dust suppression fogging systems; sound attenuation enclosures; quicksetup hydraulic support legsfor mobile plants.

Service Packages: Choose from scheduled maintenance plans offering guaranteed parts availabilityand fixed annual coststo comprehensive uptime agreements that include wear part coverageand priority field service.

Financing Options Available include equipment leasing structures that preserve capital,fleet rental programsfor projectbased needs,and traditional financingthrough partner institutions.Flexible terms are structuredto align payment scheduleswith your project cash flow.

8.FAQ

Q1 Are these plants compatible with our existing conveyorsand feeders?
A Yes.The equipmentis designedwith industrystandardinterfacedimensionsand chutework.Customizationkits are availableto ensure integrationwith legacy infrastructure.Control systemscan be specifiedto operateas a standaloneunitor as partof a centralplant PLC.

Q2 Whatisthe typical lead timefor deliveryof acustomconfiguredstationaryplant?
A Lead timesvaryby complexity.For standardheavydutyconfigurationslead time averagesbetween1824weeksfrom orderconfirmationto shipment.Mobileplantson standardchassishave shorterlead timesof approximately1216weeks.

Q3 Howdoesthe automationpackageimpactour existingoperators?
A The IntelligentProcessAutomation(IPA)is designedto assistoperatorsnot replacethem.It reducesburdensomemanualadjustmentallowingstaffto focuson overallplant optimizationand preventativechecks.Trainingis providedto ensureyour teamcan effectivelyutilizethediagnosticdata.

Q4 Canwearpartcostsbe guaranteedunder aservice agreement?
A Yes.Performancebasedservice agreementscan establishacostpertonratefor specifiedwear components.This convertsa variableoperatingexpenseinto a fixedpredictablecostsimplifyingbudgetingand providingprice certaintyoverthe contractterm.Conditionsapplybasedon feedmaterialanalysis.

Q5 Whatlevelof foundationsupportis requiredforthe stationaryplant configurations?
A Detailedcivil engineeringdrawingsare providedwith eachorder.Generallyprimarycrushersandscreensrequiresubstantialreinforcedconcretefoundationswhile secondaryunitsmay be mountedon heavydutyIbeamsframing.Sitespecificgeotechnicalreviewis recommendedas partof our predeliverysupport