1. PAINPOINT DRIVEN OPENING

Are you managing a highvolume aggregate operation and facing persistent bottlenecks that cap profitability? For plant managers and engineering contractors, a 250300 tph stone crushing plant is a critical production asset, yet common operational challenges directly impact your bottom line.

Inconsistent Throughput & Unplanned Downtime: Feed variability and component failures can cause output to fall below the 250300 TPH design capacity, leading to missed delivery schedules and costly idle time for downstream equipment and personnel.
High Operational & Maintenance Costs: Frequent liner changes, excessive energy consumption per ton, and reactive maintenance on critical crushers and screens erode profit margins. Are your maintenance costs exceeding industry benchmarks?
Final Product Quality Variance: Inconsistent gradation and excessive flakiness can lead to product rejection or downgrading, forcing reprocessing and wasting valuable plant capacity.
Regulatory Compliance & Environmental Pressure: Can your current setup reliably meet dust emission and noise control standards without compromising throughput, avoiding fines and project delays?

The central question is: how can you achieve sustained, reliable production at the 250300 TPH range while controlling costs and ensuring product specification compliance?

2. PRODUCT OVERVIEW: ISOCERTIFIED 250300TPH STONE CRUSHING PLANT

This solution refers to a complete, stationary or semimobile crushing and screening circuit engineered for consistent output of 250 to 300 metric tons per hour of crushed stone aggregates. Designed from inception under ISO 9001 quality management protocols, it ensures standardized manufacturing, traceable components, and repeatable performance.

Operational Workflow:
1. Primary Reduction: Large feed material (up to 750mm) is introduced into a robust primary jaw crusher for initial size reduction.
2. Intermediate Crushing & Screening: Crushed material is conveyed to a secondary cone crusher. A dedicated screen classifies material, routing onspec product to stockpile and oversize back for further crushing.
3. Tertiary Shaping (Optional): For highquality cubical aggregates, a tertiary vertical shaft impact (VSI) crusher can be integrated to shape the product.
4. Final Screening & Stockpiling: Multipledeck final screens separate the output into precise specification fractions (e.g., 05mm, 510mm, 1020mm), which are conveyed to designated stockpiles.

Application Scope: Ideal for largescale quarry operations, major infrastructure projects (highways, railways), and commercial concrete/asphalt plant feed. Best suited for mediumhard to hard abrasives like granite, basalt, and limestone.

Limitations: Not designed for very smallscale (<100TPH) operations or for processing highly cohesive or claybound materials without preprocessing. Plant footprint requires significant prepared space.

3. CORE FEATURES

Automated Process Control | Technical Basis: PLCbased system with loadsharing algorithms | Operational Benefit: Operators manage the entire plant from a single control station; system autoregulates feeders and crushers to prevent choking or running empty | ROI Impact: Up to 15% reduction in energy waste; enables operation with fewer personnel.

Modular Skid Design | Technical Basis: Preassembled structural steel skids with integrated walkways | Operational Benefit: Reduces onsite civil work and installation time by an estimated 30%. Simplifies future plant reconfiguration or relocation. | ROI Impact: Lower capital installation costs; faster timetorevenue from commissioning.

HeavyDuty Crusher Selection | Technical Basis: Utilization of proven jaw/cone crusher models with oversized bearings & hydraulic adjustment | Operational Benefit: Handles peak load conditions; wear part changes are faster via hydraulic tools; consistent CSS maintains product gradation. | ROI Impact: Higher availability (>94%); reduced labor hours per maintenance event.

Centralized Dust Suppression | Technical Basis: Encapsulated transfer points with strategically placed spray nozzles connected to a highcapacity pump system | Operational Benefit: Actively controls dust at source points (crusher inlets/screens/discharge), improving site visibility and operator health. | ROI Impact: Minimizes risk of regulatory noncompliance fines; reduces housekeeping labor.

Hybrid Power Configuration | Technical Basis: Plant sections can be configured for grid connection or integration with diesel gensets | Operational Benefit: Provides operational flexibility in areas with unstable grid power; enables phased electrical hookup during installation. | ROI Impact: Eliminates fullsite production stoppages due to temporary power loss.

Advanced Wear Protection | Technical Basis: Hardox® liners in hoppers/chutes; replaceable abrasionresistant steel plates at all impact zones | Operational Benefit: Dramatically extends service life of structural components subject to highwear; contains replacement downtime to predefined maintenance windows. | ROI Impact: Lowers longterm costperton for structural upkeep; protects asset integrity.

Integrated Safety Systems | Technical Basis: Zerospeed switches on conveyors, emergency stop pull cords, guarded drive units, lockout/tagout points| Operational Benefit: Protects your workforce by design through engineered hazard controls accessible during routine tasks.| ROI Impact: Reduces risk of costly accidents and associated downtime/project delays.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Plant) | ISOCertified 250300TPH Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Equipment Effectiveness (OEE)| ~82% Affected by unplanned stops & speed losses| Targeted >90% Via reliability engineering & process control| +810% more productive runtime |
| Energy Consumption (kWh/ton)| Varies widely; often not optimized as a system| Systemengineered motors & load management| Up to 12% reduction documented |
| Mean Time Between Failure (MTBF) Crushers)| Standard warranty/service intervals| Extended intervals via component derating & filtration| Approximately 20% longer service cycles |
| Installation & Commissioning Time| 812 weeks from delivery start| Estimated 68 weeks due to modularity & pretesting| ~25% faster deployment |
| Product Gradation Consistency (± % from spec)| Can exceed ±5% with manual adjustment/ wear|< ±3% maintained via automated CSS control & screening efficiency| Improved yield of premiumgrade product |

5. TECHNICAL SPECIFICATIONS

Design Capacity: Guaranteed output range of 250 300 metric tons per hour of crushed aggregate (dependent on feed material hardness < Mohn's scale 7).
Primary Crusher: Jaw Crusher Model [e.g., JC5460 equivalent], Feed Opening approx.1400x1100mm.
Secondary Crusher: Cone Crusher Model [e.g., CH660 equivalent], equipped with ASRi™ or similar automated control.
Screening Units: Heavyduty vibrating screens totaling minimum deck area of [e.g.,] >25 sqm across the circuit.
Power Requirements: Total installed power ~500 600 kW. Primary voltage requirement typically at [e.g.,]400V/50Hz or customized.
Key Material Specifications: Main frame structure fabricated from S355JR steel; Conveyor belting minimum EP630/4 specification; Highstrength bolts throughout.
Physical Dimensions (Approx.): Plant length ~75m x width ~25m x max height ~15m (varies by layout).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with optional packages for more extreme conditions.

6. APPLICATION SCENARIOS

Large Granite Quarry Expansion

Challenge A quarry needed to increase production from200 TPHtoa steady280 TPHto fulfill anew highway contract but was constrained by an aging,twostageplant prone todowntimeand poor cubicityfor asphalt chips.
Solution ImplementationofanewISOcertifiedthreestage250300TPHplant featuring aprimary jaw ,secondary cone,andtertiary VSI crusherinaclosedcircuitlayoutwith advanced screening .
Results Plant achieved anaverageoutputof290 TPHofhighqualitycubicalaggregates.Availability reached92%inthefirstyear.Product yieldinthepremium"chipping"gradesincreasedby22%,directly boostingcontractmargin .

Major Infrastructure Contractor

Challenge A contractorfor alargescalerailproject requiredahighcapacitytemporary crushingplant tomobileprocessexcavated rockonsite tomeetstrictfillmaterial specificationsandminimize haulingcosts .
Solution Deploymentofasemimobileversionofthe250300TPHplantonmodularskids .Theplant wascommissionedwithin7weeksofdeliveryandconfiguredforquickrelocationbetweensiteprogressions .
Results Theplantsuppliedover1 .2milliontonsofonspecmaterialover18months ,eliminatingexternalaggregatepurchaseandassociatedlogistics .Projectreportsshowedacost savingofapproximately18%onfillmaterialprovisionagainsttheoriginalbudget .

7.COMMERCIAL CONSIDERATIONS

Equipment pricing forturnkeyISOcertified250–300TPHstonecrushingplantsisstructuredintotiersbasedonconfigurationcomplexity :

• Tier1(StandardTwoStage): Includesprimaryjaw ,secondarycone ,basicscreening,andconveyors .Focusesonreliablevolumeproduction .
• Tier2(AdvancedThreeStage): AddsatertiaryVSIcrusherforsuperiorproductshaping ,enhanceddustcontrolsystems ,andmorecomprehensiveprocessautomation .
• Tier3(Customized): Incorporates specificfeeders ,washing systems ,orextendedstockpileconveyorsbasedonprojectgeologyandfinalproductslate .

OptionalFeatures Includeenclosedacousticcabinssignificantlyreducingnoisefootprint ,automatedgreasing systemsforcriticalbearings ,andremotemonitoringtelematics .

ServicePackages Availablefrombasicwarrantysupporttocomprehensiveannualserviceagreementscoveringplannedmaintenance ,wearpartsinventorymanagement ,andprioritytechnicalsupport .

FinancingOptions Flexiblecommercialstructuresareavailableincludingstraightequipmentpurchase ,operationalleasearrangements tomatchprojectduration,andfinancethroughpartnered institutions .

8.FAQ

Q1:Arewesequipmentbrandsusedinyourplants?
A1 OurISOcertifiedplantsareengineeredusingseriesprovencorecrushingandscreeningmachineryfrominternationallyrecognizedmanufacturers .Specificmodelsareselectedbasedonthematerialtestdatatomeetyourcapacityandproductgoals .

Q2:Canyourplantintegratewithourexistingprimarycrusherorexcavator?
A2 Yes .Theplantdesigncanbecustomizedtoreceivematerialfromyourexistingprimarysource .Feedhopperdimensionsandreceivingcapacitiesareengineeredtomatchyourupstreamequipment 'soutputtopreventbottlenecks .

Q3:Whatisthetypicalleadtimefromordertocommissioning?
A3 Forstandardconfigurations leadtimeisapproximately20–26weeks Excludingsitecivilworkswhichcanproceedinparallelwithmanufacturing Thisincludesfactoryassemblytestingbeforedispatch

Q4 Howdoesyoursolutionaddressenergysavingsspecifically?
A4 Energyoptimizationissystemic Itincludescorrectmotorsizing variablefrequencydrivesonconveyors loadsensinghydraulicsoncrushersandanautomatedcontrolsystemthatpreventsnoloadrunning FielddatashowspeakdemandreductioncontributingtothelowerkWhpertonmetric

Q5 Whattrainingisprovidedforouroperatorsandmaintenancestaff?
A5 We provide comprehensive onsite training covering normal operation troubleshooting procedures safety protocols preventative maintenance schedules We also supply detailed digital manuals part lists schematics

Q6 Areyourplantsdesignedformaintenanceaccessibility?
A6 Yes Maintenanceaccessisacentraldesigncriteria Platforms ladders walkways allow safereachtoallroutinecheckpoints Crushersfeature hydraulic adjustment settings clearing systems reducing downtime Liner changeout procedures are engineered forefficiency

Q7 Whatkindofperformanceguaranteesareoffered?
A7 We provide guaranteed minimum capacity based on your specific material test results Additionally we guarantee that the plant as supplied will comply with stated noise emission levels under standard operating conditions