1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? In aggregate production, mineral processing, and recycling, inefficient crushing and screening is a primary bottleneck. Common challenges include:
Excessive Downtime for Maintenance: Frequent liner changes, bearing failures, and conveyor issues halt your entire production line.
Inconsistent Product Gradation: Poor screening efficiency and improper crushing chamber dynamics lead to offspec material, causing product rejection and revenue loss.
High Operational Costs: Rising energy consumption per ton, coupled with high wear part replacement frequency, directly impacts your bottom line.
Rigid Plant Configuration: Fixed systems cannot adapt to changing feed material or final product requirements, limiting operational flexibility.

Is your current equipment addressing these issues, or is it the source of them? The right primary crushing station is not just a purchase; it’s a strategic decision for longterm site profitability.

2. PRODUCT OVERVIEW: PRIMARY CRUSHING AND SCREENING STATION

This primary crushing and screening station is a fullyintegrated, trackmounted or modular system designed for the initial size reduction of runofmine ore, quarry rock, or demolition concrete. Its workflow is engineered for continuous heavyduty operation:
1. Feed: Material is deposited via excavator or wheel loader into a robust vibrating grizzly feeder.
2. PreScreening & Crushing: The grizzly bypasses fines directly to a conveyor while oversize material is directed into the highcapacity jaw crusher.
3. Primary Crushing: The jaw crusher performs the first mechanical reduction using compressive force.
4. PostCrushing Screening: Crushed material is conveyed to an integrated screen for immediate separation into required product fractions.
5. Stockpiling or Secondary Conveyance: Sized fractions are stockpiled or conveyed to the next stage of processing.

Application Scope: Ideal for hard rock mining, aggregate quarries, largescale construction projects, and C&D recycling operations requiring highvolume primary reduction.
Limitations: Not designed for final product shaping (tertiary crushing) or processing highly abrasive materials without specific liner configurations. Feed size must adhere to crusher opening specifications.

3. CORE FEATURES

Direct Drive Jaw Crusher | Technical Basis: Eliminates Vbelts and associated components | Operational Benefit: Reduces power transmission losses and removes routine belt tensioning/maintenance | ROI Impact: Field data shows up to 10% lower fuel consumption and 15% less scheduled maintenance time.

Independent PreScreen Module | Technical Basis: Twodeck vibrating grid mounted ahead of the crusher | Operational Benefit: Removes fines and natural sand from the crusher feed, reducing chamber wear and increasing throughput of valuable midsize material | ROI Impact: Can extend manganese liner life by up to 30% and increase total station output.

Hydraulic Setting Adjustment (HSA) | Technical Basis: Wedgebased chamber adjustment via hydraulic cylinders | Operational Benefit: Allows operators to change the crusher closedside setting (CSS) in under 2 minutes for precise product size control without stopping the plant | ROI Impact: Minimizes nonproductive time during product changeovers by over 90%.

HeavyDuty Feeder with Step Grizzly | Technical Basis: Reinforced feeder with stepped grizzly bars to prevent clogging | Operational Benefit: Ensures consistent feed flow even with sticky or claybound materials, preventing bridging and feeder stall | ROI Impact: Maintains target throughput rates in challenging conditions, avoiding costly flow interruptions.

Integrated Plant Automation System (IPAS) | Technical Basis: PLCbased control with touchscreen interface monitoring all critical functions | Operational Benefit: Provides realtime data on production rates, power draw, and operational status; enables singlepanel control for setup and troubleshooting | ROI Impact: Improves overall equipment effectiveness (OEE) through better monitoring and reduces diagnostic time by an average of 50%.

Centralized Greasing Points | Technical Basis: Manifold system linking all major bearing points to a single station | Operational Benefit: Enables safe, rapid daily lubrication checks without requiring access around moving components | ROI Impact: Standardizes preventive maintenance routines, enhancing bearing life and reducing lubricationrelated failures.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | This Primary Crushing & Screening Station | Advantage (% Improvement) |
| : | : | : | : |
| Tons per Hour (TPH) Efficiency| Reliant on optimal feed conditions only| Maintains >90% of rated TPH with variable/ sticky feed due to step grizzly design| +1520% sustained output |
| Wear Part Cost per Ton| Based on standard manganese composition| Utilizes sitespecific alloy analysis for jaw liners in highabrasion applications| Up to 25% cost per ton crushed |
| Setup / Configuration Time| Multiple machine positioning & cable connections required| Singlelift modules with prerigged electrical connections between units| 70% relocation time |
| Energy Consumption (kWh/ton)| Direct mechanical drive with fixed speed motors| Loadsensing hydraulics & direct electric crusher drive adjust power to demand| 8% average energy use |

Based on comparative field trials in granite quarry applications.

5. TECHNICAL SPECIFICATIONS

Primary Crusher Type: Nordberg C106 Jaw Crusher
Feed Opening: 1,060 mm x 700 mm (42” x 28”)
Maximum Feed Size: 600 mm (24”)
Closed Side Setting (CSS) Range: 70 200 mm
Capacity Range: Up to 500 Mtph (dependent on material density & CSS)
Power Unit: CAT C9 / C9.3 ACERT Tier 4 Final diesel engine
Total Installed Power: 224 kW
Feeder Type: Vibrating Grizzly Feeder VG43912V
Screen Module: Twodeck inclined screen TS303
Main Conveyor Width: 1,000 mm
Transport Dimensions (LxWxH): ~19m x ~3m x ~4m
Operating Weight: ~45 tonnes
Operating Temperature Range: 25°C to +40°C

6. APPLICATION SCENARIOS

Granite Aggregate Quarry Expansion | Challenge: Existing fixed primary plant could not service new pit face location without major infrastructure cost; mobile solutions lacked necessary throughput and prescreening. Solution: Deployment of a trackmounted primary crushing and screening station fed directly by excavator at the new face. Results: Eliminated need for costly ramp construction and dump truck haulage to old plant. Achieved consistent throughput of 380 Mtph of minus200mm base material with improved yield of valuable railway ballast fraction due to integrated screening.

LargeScale Infrastructure Project (Dam Construction) | Challenge: Processing riverrun gravel with high sand content led to rapid crusher wear choke points in traditional setups. Solution Implementation of a modular primary station featuring an independent prescreen module ahead of the jaw crusher Results Prescreen removed over 25% of sand/fines prior to crushing reducing abrasive wear Throughput increased by18% as crusher processed only oversize Wear part replacement intervals extended by approximately40%

7 COMMERCIAL CONSIDERATIONS

Pricing for a primary crushing station varies significantly based on configuration:

• Base Configuration Includes core jaw crusher basic feeder engine chassis essential conveyors PLC start/stop controls Tier pricing typically begins in range appropriate for this capital equipment class

Optional Features That Add Value:

• Dust suppression system package including water tank spray bars
• Magnet installation over discharge conveyor ferrous metal removal
• Radio remote control unit for independent feeder/crusher operation from ground level
• Extended wear part kits stock

Service Packages Available:

• Comprehensive Extended Warranty covering major components years unlimited hours
• Scheduled Maintenance Plan providing fixed cost annual inspections parts labor
• On Site Operator Training Program days hands instruction

Financing Options Flexible capital solutions include equipment leasing long term rental purchase leaseback structures tailored support cash flow management project timelines

8 FAQ

What type/size of excavator is recommended as a feeder?
A minimum operating weight class excavator equipped with suitable bucket capacity ensure consistent choke feeding maximize crusher efficiency productivity

How does this system handle reinforcing bar rebar in concrete demolition waste?
While jaw can process reinforced concrete integrated overband magnet discharge conveyor effectively removes liberated ferrous metals protecting downstream conveyors secondary crushers

What are typical delivery lead times after order confirmation?
Standard configurations have confirmed lead time weeks subject build slot availability engineering review Custom modular designs may require additional weeks detailed engineering fabrication

Is operator training provided with purchase?
Yes comprehensive onsite training program conducted commissioning covers daily operation routine maintenance safety procedures troubleshooting using actual plant systems

Can this station be integrated into existing fixed plant circuit as temporary primary unit?
Yes stations are designed standalone mobility can be positioned feed directly into existing secondary tertiary circuits via discharge conveyor ideal use during planned upgrades maintenance existing primary crushers