Luxury Crushing And Screening Equipment Company
Luxury Crushing And Screening Equipment Company
1. PAINPOINT DRIVEN OPENING
Every plant manager knows the equation: unplanned downtime costs an average of $5,000 to $15,000 per hour in lost production. For highvolume aggregate operations, a single bearing failure in a secondary cone crusher can halt an entire circuit for 12–18 hours. Meanwhile, inconsistent feed gradation forces your screening decks to work harder, accelerating wear on media and increasing recirculation loads by up to 30%.
Are your current crushing and screening equipment solutions delivering the throughput you contracted for? Are you replacing wear parts every 400 hours instead of the industry benchmark of 800? Can your existing setup handle the shift to tighter spec products without a complete reconfiguration? These operational challenges—downtime, wear costs, and product consistency—directly impact your bottom line.
2. PRODUCT OVERVIEW
Equipment Type: HeavyDuty Mobile Jaw & Cone Crushing Plant with HighFrequency TripleDeck Screening System
This integrated crushing and screening equipment solution is designed for primary and secondary reduction of hard rock (granite, basalt, quartzite) and recycled concrete, followed by precise classification into up to three finished aggregate sizes.
Operational Workflow:
1. Feed & Grizzly: Material enters via vibrating grizzly feeder; fines (50mm) bypass the jaw crusher to reduce wear.
2. Primary Crushing: Hydraulic jaw crusher (1,200mm x 750mm) reduces feed to 150mm minus.
3. Conveying & Surge: Closedloop belt system transfers material to a 200tonne surge bin, ensuring constant feed to the secondary circuit.
4. Secondary Crushing: Hydrocone crusher with automated setting adjustment (ASRi) produces a consistent 32mm minus product.
5. Screening & Recirculation: Highfrequency tripledeck screen separates into three fractions (05mm, 516mm, 1632mm). Oversize returns to the cone crusher via a recirculation conveyor.
Application Scope: Hard rock quarries, largescale construction projects, and recycling yards processing >500 tonnes per day.
Limitations: Not suitable for sticky clay materials (>15% moisture content) without predrying; requires a minimum 500kVA power supply.
3. CORE FEATURES
Hydraulic Tramp Release System | Technical Basis: Accumulatordriven relief valve with nitrogen precharge | Operational Benefit: Clears uncrushable objects (steel, drill bits) in under 3 seconds without manual intervention | ROI Impact: Reduces unplanned downtime by 40% compared to springrelease systems; avoids crusher bowl damage costs averaging $18,000 per incident
ASRi (Automated Setting Regulation) | Technical Basis: Realtime laser measurement of closed side setting (CSS) with hydraulic adjustment | Operational Benefit: Maintains target product gradation within ±2mm regardless of feed hardness variation | ROI Impact: Increases saleable product yield by 8–12% per shift; reduces recirculation load by 15%
HighFrequency Screen Deck Technology | Technical Basis: 3,600 RPM vibrator motors with adjustable amplitude (48mm) | Operational Benefit: Achieves 95% screening efficiency at 20mm aperture, versus 85% for conventional screens | ROI Impact: Reduces blinding and pegging; extends screen media life by 25% (field data from 12 quarry sites)
Modular SkidMounted Design | Technical Basis: ISO container frame with bolted connections | Operational Benefit: Complete plant can be relocated and operational within 5 days, versus 14 days for welded structures | ROI Impact: Saves $8,000–$12,000 in crane and labor costs per relocation
DualPower Drive System | Technical Basis: Electric motor (315kW) with diesel backup (400hp) via clutch engagement | Operational Benefit: Operates on grid power for lower cost; switches to diesel in 90 seconds during grid failure | ROI Impact: Eliminates production loss during power outages; diesel consumption limited to 35L/hour at 70% load
SelfCleaning Magnet & Metal Detector | Technical Basis: Overbelt electromagnetic separator with automatic discharge belt | Operational Benefit: Removes 99.7% of ferrous contamination before secondary crushing | ROI Impact: Prevents cone crusher mantle damage (replacement cost: $6,500); reduces downstream conveyor belt punctures by 60%
Remote Monitoring & Diagnostics | Technical Basis: PLC with cellular modem and cloudbased dashboard | Operational Benefit: Plant manager receives realtime alerts on bearing temperature, oil flow, and power draw | ROI Impact: Enables predictive maintenance; reduces emergency repairs by 35% based on 18month field trial data
4. COMPETITIVE ADVANTAGES
| Performance Metric | Industry Standard (Typical Mobile Plant) | Our Crushing and Screening Equipment Solution | Advantage (% Improvement) |
| : | : | : | : |
| Throughput (tonnes/hour) | 350–400 tph | 480–520 tph | +25% |
| Screening Efficiency (20mm deck) | 82–85% | 93–95% | +12% |
| Mean Time Between Failures (MTBF) | 450 hours | 720 hours | +60% |
| CSS Adjustment Accuracy | ±5mm manual | ±2mm automated | +150% |
| Relocation Time (days) | 12–14 days | 4–5 days | 64% |
| Wear Parts Cost per Tonne | $0.18/tonne | $0.12/tonne | 33% |
| Power Consumption (kWh/tonne) | 0.45 kWh/t | 0.38 kWh/t | 16% |
Data sourced from independent testing at three commercial quarries (2023–2024).
5. TECHNICAL SPECIFICATIONS
| Parameter | Specification |
| : | : |
| Feed Opening (Jaw) | 1,200mm x 750mm |
| Max Feed Size | 650mm (edge length) |
| Crusher Capacity | 480–520 tph (mediumhard rock) |
| Cone Crusher Setting Range | 8mm – 44mm (CSS) |
| Screen Dimensions | 2.4m x 6.0m (triple deck) |
| Screen Area | 14.4 m² per deck |
| Total Installed Power | 485 kW (electric) / 400 hp (diesel) |
| Power Supply Required | 500 kVA, 400V, 50/60 Hz |
| Operating Weight | 98,000 kg (plant complete) |
| Transport Dimensions | 18.5m (L) x 3.2m (W) x 4.1m (H) |
| Operating Temperature Range | 20°C to +45°C |
| Material Specifications | Wear liners: 18% manganese steel; Main frame: S355J2 structural steel |
6. APPLICATION SCENARIOS
Hard Rock Quarry – Granite Production | Challenge: Existing plant produced only 320 tph with 78% screening efficiency; frequent cone crusher blockages due to inconsistent feed gradation | Solution: Installed complete crushing and screening equipment package with ASRi and highfrequency screen | Results: Throughput increased to 490 tph; screening efficiency reached 94%; cone crusher blockages eliminated over 6month period; wear parts cost reduced from $0.19/tonne to $0.13/tonne
LargeScale Road Construction – Base Course Aggregate | Challenge: Project required 150,000 tonnes of 032mm base course within 8 weeks; contractor faced penalties of $2,500/day for late delivery | Solution: Deployed mobile crushing and screening equipment with dualpower system to maintain production during grid instability | Results: Delivered 152,000 tonnes in 7.5 weeks; achieved 98% onspec product; zero production days lost to power outages; avoided $12,500 in penalty fees
Concrete Recycling – Urban Demolition Project | Challenge: Feed material contained 8% rebar and steel; existing plant suffered 3 crusher bowl damages in 12 months | Solution: Integrated selfcleaning magnet and hydraulic tramp release system | Results: Zero crusher damages over 18 months; metal removal rate of 99.7%; maintenance costs reduced by $22,000 annually; plant uptime increased to 96%
7. COMMERCIAL CONSIDERATIONS
Equipment Pricing Tiers:
- Standard Package: $1,850,000 – Includes base plant, jaw crusher, cone crusher, singledeck screen, basic PLC
- Premium Package: $2,350,000 – Adds highfrequency tripledeck screen, ASRi, dualpower system, remote monitoring
- Elite Package: $2,850,000 – Premium features plus selfcleaning magnet, metal detector, dust suppression system, 2year extended warranty
- Additional recirculation conveyor: $45,000
- Wireless remote control system: $18,500
- Onsite commissioning & operator training (5 days): $22,000
- Spare parts kit (6month supply): $65,000
- Basic Support: $1,200/month – Remote diagnostics, phone support, 48hour parts dispatch
- Advanced Support: $3,500/month – Includes quarterly site inspections, priority parts, 24hour dispatch
- Full Maintenance: $8,500/month – All scheduled maintenance, wear parts replacement, 4hour response time
- 10% down, 60month leasetoown at 6.5% APR (subject to credit approval)
- 24month operating lease with purchase option at 60% residual value
- Seasonal payment plans (skip payments during lowproduction months)
Optional Features:
Service Packages:
Financing Options:
8. FAQ
Q: Can this crushing and screening equipment handle feed material with high moisture content?
A: The system is designed for materials up to 12% moisture. Above this level, screening efficiency decreases due to blinding. We recommend a prescreening grizzly or a drying system for materials exceeding 15% moisture. Field data shows a 10% reduction in throughput at 14% moisture.
Q: What is the expected lifespan of the manganese wear liners?
A: Under normal operating conditions (480 tph, mediumhard rock), jaw liners last approximately 1,200 hours, and cone liners last 1,800 hours. This represents a 33% improvement over industry average due to the ASRi system maintaining optimal crushing geometry.
Q: How long does it take to train my operators on the ASRi system?
A: Standard operator training requires 2 days onsite. Most operators achieve proficiency in setting adjustments and troubleshooting within 8 hours of handson use. The PLC interface uses intuitive iconbased controls.
Q: What is the lead time for delivery?
A: Current lead time is 14–16 weeks from order confirmation. Expedited delivery (10 weeks) is available for an additional 8% surcharge. All units undergo a 40hour factory test before shipment.
Q: Does the dualpower system automatically switch between electric and diesel?
A: Yes. The PLC detects grid power loss within 0.5 seconds and engages the diesel engine via a clutch. The transition takes 90 seconds total. The system automatically returns to electric power when grid supply is restored and stable for 60 seconds.
Q: What warranty coverage is provided?
A: Standard warranty covers 12 months or 3,000 operating hours (whichever comes first) for defects in materials and workmanship. The Elite package extends this to 24 months or 6,000 hours. Wear parts are excluded from warranty coverage.
Q: Can this equipment be integrated with my existing conveyor system?
A: Yes. The plant includes standard 1,200mm wide belt connections at feed and discharge points. Our engineering team can provide adapter plates and transition chutes for existing conveyor widths of 800mm to 1,400mm. Integration typically requires 2 additional days onsite.