1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your plant's profitability? In industrial crushing and screening, common challenges directly impact your bottom line. Excessive wear part consumption leads to frequent, costly replacements and unplanned maintenance windows. Inconsistent feed material causes fluctuating product gradation, resulting in outofspec material and rejected loads. Energyintensive processes consume disproportionate power without corresponding output gains. Furthermore, frequent clogging and bridging in the circuit halt entire production lines, while complex maintenance procedures keep skilled technicians occupied for hours instead of optimizing throughput.

How do you transition from reactive repairs to predictive, costcontrolled operations? The solution lies in selecting industrial crushing and screening equipment engineered to convert these pain points into measurable efficiency gains.

2. PRODUCT OVERVIEW

This product line encompasses heavyduty stationary and semimobile crushing plants and screens designed for hightonnage mineral processing, aggregate production, and construction material recycling. The operational workflow is engineered for continuous, closedcircuit operation: (1) Primary feed is reduced by a jaw or gyratory crusher. (2) Material is conveyed to a secondary cone or impact crusher for further reduction. (3) Sized material is routed via conveyor to a multideck vibrating screen for classification. (4) Onspec product is diverted to stockpile, while oversize material is recirculated back into the secondary or tertiary crusher.

This equipment is applicable for processing hard rock (granite, basalt), abrasive ores, limestone, and recycled concrete/asphalt. It is not designed for lowvolume, batch processing or for materials with high plasticity or clay content without specific preprocessing.

3. CORE FEATURES

Modular Chamber Design | Technical Basis: Interchangeable crushing chamber profiles and eccentric throws. | Operational Benefit: Enables quick reconfiguration from secondary to tertiary application or between different product shapes without major component changeouts. | ROI Impact: Reduces capital expenditure for a dedicated tertiary crusher by up to 40% in flexible plant designs.

Hydroset CSS Adjustment | Technical Basis: Hydraulic system for Closed Side Setting (CSS) adjustment under load.| Operational Benefit: Allows operators to finetune product size in under 60 seconds without stopping production, adapting to changing feed conditions in realtime.| ROI Impact: Eliminates production stoppages for manual shim adjustments, preserving an estimated 2030 hours of annual uptime per crusher.

Patented Screenbox Motion | Technical Basis: HighGforce linear or elliptical vibration drive technology tailored to material type.| Operational Benefit: Prevents blinding and pegging of screen meshes while maintaining high stratification efficiency for accurate sizing.| ROI Impact: Increases screening efficiency by up to 15%, reducing recirculating load on crushers and lowering energy cost per ton.

Wear Part Monitoring System | Technical Basis: Embedded sensor technology paired with IoTenabled wear tracking software.| Operational Benefit: Provides realtime data on liner thickness and predicts optimal changeout times based on actual wear rates, not just hours operated.| ROI Impact: Maximizes usable wear part life by 1218% on average and allows maintenance scheduling during planned outages, avoiding catastrophic failure.

Direct Drive Crusher Transmission | Technical Basis: Elimination of Vbelts via direct coupling of motor to crusher drive.| Operational Benefit: Increases power transmission efficiency by approximately 5%, reduces maintenance points (no belt tensioning), and lowers overall installed footprint.| ROI Impact: Direct energy savings coupled with reduced spare parts inventory (belts, sheaves) yield a typical payback period under 24 months.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Crushing & Screening Solution | Advantage (% improvement) |
| : | : | : | : |
| Tons per kWh (Energy Efficiency) | Measured baseline from legacy equipment surveys. | Optimized chamber geometry & direct drive systems reduce specific energy consumption. | Up to 812% improvement |
| Wear Part Cost per Ton Processed | Based on standard manganese steel compositions & profiles. | Proprietary alloy formulations & engineered laminating crushing zones extend service life. | 1525% reduction demonstrated |
| Mean Time Between Failure (MTBF) – Drives/Screens | Average intervals from industry maintenance reports. | Heavyduty bearing assemblies & balanced mass design reduce stress on components. | 30%+ increase documented |
| Screening Accuracy / Fines Yield Control| Standard singlefrequency screen box performance.| Multifrequency capable drives optimize particle travel speed & trajectory per deck.| Fines yield control improved by up to 10% |

5.TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 TPH to over 1,500 TPH primary crushing circuits.
Power Requirements: Plantwide requirements range from 400 kW to 1.5 MW; supplied for global voltages (380V480V/5060Hz). Crusher motors typically 200450 kW each.
Material Specifications: Fabricated from hightensile steel plate; Crusher liners available in multiple grades of manganese steel (14%22%) or optional chromewhite iron alloys; Screen decks in hardened steel wire mesh or polyurethane panels.
Physical Dimensions (Sample Primary Unit): Feed hopper: ~12m³; Crusher itself: L~5m x W~3m x H~4m; Total station footprint including feeders: ~25m x 15m.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dustsealed bearings and drives; sounddampened enclosures available to meet <85 dB(A) at operator stations.

6\. APPLICATION SCENARIOS

[Aggregate Producer – Granite Quarry]

Challenge: A quarry faced inconsistent cubicity in final aggregate products due to fluctuating rock strata hardness, leading to poor compaction rates reported by road construction clients.
Solution: Implementation of a cone crusher with automated Hydroset system and an advanced multideck screen within their closed circuit.
Results: Realtime CSS adjustment stabilized product shape (% cubicity). Field data shows a consistent improvement of over 22% in flakiness index, eliminating product rejection and allowing a premium product price point.

[Iron Ore Processing Plant]

Challenge: Extreme abrasiveness of ore resulted in unsustainably high wear part costs in secondary crushing stages (850 hours—a ~40% increase—and monitoring enabled justintime changes during shift breaks.This reduced annual planned downtime related to liner changes by approximately 120 hours.

7\. COMMERCIAL CONSIDERATIONS

Industrial crushing and screening equipment pricing is tiered based on capacity throughput:
Tier I (1000 TPH): Fully customengineered systems with process simulation integration.

Optional features include advanced dust suppression systems fully integrated with water recycling plants,tiremounted mobile crawler systems,and centralized automated lubrication systems.Service packages are structured as Bronze (parts only), Silver (parts + scheduled maintenance),and Gold (fullsite service agreement including condition monitoring data analysis).Financing options include capital lease agreements tailoredto align payments with projected production revenue increases,and operating leases that include full service coverage.

8\. FAQ

Q1: Is your equipment compatible with our existing conveyor infrastructure?
A1: Our engineering team conducts presale audits.Crushers,screens,and feeders can be interfaced with existing conveyors provided load capacities match.We supply necessary transition chutes,support structures,and control system interfaces as part of the scope.

Q2:What level of operational disruption should we expect during installation?
A2:A detailed Site Implementation Plan minimizes disruption.For greenfield sites,there is no impact.For brownfield retrofits,a phased approach typically allows partial plant operation.Field data indicates full integration can be completed within a preagreed shutdown window of1421 daysfor most mediumcomplexity circuits

Q3:What are the commercial terms regarding warranty?
A3:The standard warranty covers defects in materials/workmanshipfor12 monthsfrom commissioning.Extended structural warranties(upto60 monthson main frames)and performance guarantees(on throughputand power draw)are available subjectto agreed feed specifications

Q4:What operator trainingis provided?
A4:A comprehensive program includes classroom instructionon principlesof operation,safety procedures,and basic troubleshooting,followedby handson trainingat your site during commissioning.This typically spans5 daysfor lead operatorsand maintenance supervisors

Q5:What ongoing technical supportis available postpurchase?
A5:Dedicated technical supportis accessible24/7via phoneor our customer portal.Regional service engineers provide onsite support.Access todetailed parts manuals,schematic diagrams,and recommended spare parts listsis provided digitally at commissioning