1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and engineering contractors, the crushing and screening circuit is often the bottleneck. Common challenges include:
Unscheduled Downtime: Component failures in critical crushers or screeners halt entire lines, costing thousands per hour in lost production and labor.
High Maintenance Costs: Frequent wear part replacement and complex service procedures for offtheshelf equipment create significant, recurring OPEX.
Inconsistent Output & Quality: Poorly matched or inefficient ODM crushing and screening equipment leads to product gradation issues, causing recrushing cycles and rejected loads.
Rigid System Integration: Standard machinery often fails to adapt to unique site layouts or specific material characteristics, forcing costly workarounds.

What if your primary processing equipment was engineered from the ground up to address these exact pain points? What would a 1520% reduction in total cost of ownership mean for your next bid?

2. PRODUCT OVERVIEW: ODM CRUSHING AND SCREENING EQUIPMENT

Our ODM (Original Design Manufacturing) crushing and screening equipment represents a tailored approach to primary and secondary raw material processing. Unlike standard catalog models, this machinery is designed in collaboration with OEM partners to meet precise operational parameters, material specifications, and throughput targets.

Operational Workflow:
1. Primary Size Reduction: Feed material is received by a heavyduty crusher (jaw, cone, or impactor) configured for optimal reduction ratio and wear life.
2. Primary Screening: Scalping screens remove fines and bypass material before secondary crushing, increasing circuit efficiency.
3. Secondary Processing & Classification: Material is routed through secondary crushers and precision screens to achieve exact product specifications.
4. Stockpiling & Recirculation: Onspec material is conveyed to stockpile; oversize is automatically returned to the circuit.

Application Scope: Ideal for aggregates production (limestone, granite), mining prebeneficiation, C&D waste recycling, and industrial mineral processing.

Limitations: Maximum feed size and capacity are defined during the ODM design phase based on clientprovided material testing data. Equipment is not suitable as an offtheshelf solution without this collaborative specification process.

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Finite Element Analysis (FEA) & particle flow simulation | Operational Benefit: Optimized nip angles and crushing paths increase throughput by 812% while reducing power draw per ton. | ROI Impact: Lower energy costs and higher output directly improve margin per operating hour.

Unified Hydraulic & Control System | Technical Basis: Centralized proportional valve blocks with singlepoint pressure regulation. | Operational Benefit: Enables safe clearing of tramp metal and cavity clearing in under 2 minutes from the control station, minimizing stallrelated downtime. | ROI Impact: Prevents costly chainreaction breakdowns; estimated to save 3050 hours of annual downtime.

Modular Wear Component System | Technical Basis: Standardized mounting interfaces with zonespecific alloy selection (e.g., martensitic steel for impact, chrome iron for abrasion). | Operational Benefit: Reduces wear part inventory by up to 40% and cuts changeout time by an average of 25%. | ROI Impact: Lowers inventory carrying costs and reduces maintenance labor hours.

HeavyDuty Vibratory Screen Assembly | Technical Basis: Balanced mass design with highstrength side plates and controlled vibration frequency. | Operational Benefit: Maintains consistent screen cloth tensioning for sharper separation; reduces structural fatigue failures common in highcycle operations. | ROI Impact: Extends screen deck life by approximately 30%, reducing replacement part frequency.

Integrated Condition Monitoring Ports | Technical Basis: Preinstalled sensor ports (vibration, temperature) on bearings and gearboxes wired to a central junction box. | Operational Benefit: Facilitates easy connection to plant SCADA systems for predictive maintenance scheduling based on actual load conditions.| ROI Impact: Transforms maintenance from reactive to predictive, avoiding catastrophic failures that typically cost 10x more than planned interventions.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (OfftheShelf) | Our ODM Crushing & Screening Solution | Advantage |
| : | : | : | : |
| Availability / Uptime | 8590% (planned & unplanned downtime) | Target of 9496% achievable through designforreliability principles| +6% improvement |
| Tonnage per kWh (Crusher)| Baseline (100%)| Field data shows consistent gains of 812% via optimized kinematics| +10% improvement |
| Wear Part Cost per Metric Ton| Variable; high due to generic designs| Documented reductions of 1525% via applicationspecific metallurgy| 20% improvement |
| Installation & Commissioning Time| Weeks due to layout compromises & modifications| Streamlined by up to 35% through preengineered integration packages.| 35% improvement |

5. TECHNICAL SPECIFICATIONS

Specifications are determined during the ODM engagement phase; below represents a typical midrange configuration.

Capacity Range: Configurable from 150 TPH to over 800 TPH for hard rock aggregate production.
Power Requirements: Primary crusher drives from 90 kW to 315 kW; total plant power tailored to layout with options for electric or dieselhydraulic prime movers.
Material Specifications: Fabricated from S355JR structural steel; liners available in TENSAL™ AR400/500, highchrome white iron (HCWI), or manganese steel as specified.
Physical Dimensions: Modular design allows adaptation to space constraints; typical primary unit footprint of ~8m L x 3m W x 4m H.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system integration points standard; noise emissions compliant with ISO standards (<85 dB(A) at operator stations).

6. APPLICATION SCENARIOS

Aggregates Producer – Granite Quarry | Challenge: Excessive wear on cone crusher mantles/concaves due to highly abrasive silica content, causing cost overruns every six weeks.| Solution: Implementation of an ODM tertiary cone crusher with custom chamber profile paired with HCWI liners in critical wear zones.| Results: Wear life extended from ~6 weeks to ~14 weeks; liner cost per ton reduced by approximately $0.18 USD.

C&D Recycling Contractor – Urban Operation | Challenge: Need a compact, highly mobile primary crushing/screening setup capable of processing mixed debris without constant jamming.| Solution: Codesigned an ODM mobile jaw/impact combo plant with enhanced hydraulic clearing systems,a reinforced feeder,and an aggressive scalping deck.| Results: Achieved target mobility (<24hr setup); reduced jamming incidents by over 80%; increased clean aggregate yield by volume.

7. COMMERCIAL CONSIDERATIONS

Our ODM crushing and screening equipment is priced based on engineeredtoorder specifications rather than fixed list prices.

Pricing Tiers: Generally structured around capacity/complexity:
Tier I (600 TPH): Full stationary plant design with advanced automation integration.
Optional Features / Packages: Advanced PLC automation packages with touchscreen HMIs; hybrid power systems; specialized dust containment canopies; quickwear changeout kits.
Service Packages: Available as annual support contracts covering remote diagnostics, scheduled inspections,vibration analysis services,and priority parts dispatch.Guaranteed response times are contractually defined.
Financing Options: Flexible capital expenditure solutions can be arranged through our financial partners,includingsaleandleaseback arrangements,tiered payment plans aligned with project milestones,and traditional leasing structures.

8. FAQ

1. How does the ODM process ensure compatibility with our existing plant layout?
The process begins with a detailed site audit.We develop comprehensive GA drawings(General Arrangement)and interface control documents(ICDs)for client review before fabrication begins.This ensures all feed/discharge heights,material flow paths,and service access requirements are met precisely.

2.What is the typical lead time from specification agreementto commissioning?
Lead times vary significantly based on complexity.For a standard modular unit,the range is typically between18and32weeks.This includes detailed engineering,fabrication,factory acceptance testing(FAT),and shipping logistics.A detailed schedule forms part of the project charter

3.Can you provide performance guarantees?
Yes.Based on certified thirdparty laboratory test results of your representative feed sample we will provide guaranteed performance metricsfor throughput product gradation curveand maximum power consumption subjectto agreedupon feed conditions

4.What levelof technical documentationis provided?
You receivea completeasbuilt documentation pack including P&IDs electrical schematics hydraulic diagrams foundation loadings bills of materials(BOM)and recommended spare parts listsfor years one threeand fiveof operation

5.Are training services included?
Standard commissioning includes onsite trainingfor operationsand basic maintenance personnel We offer additional tiered training programs covering advanced troubleshooting predictive maintenance techniquesand control system programming

6.How do you handle parts supply after commissioning?
We maintaina dedicated parts logistics programfor ourODM clients Critical wear partsare often stocked under consignment agreements at regional hubs ensuring availability Nonstocked items followa guaranteed manufacturing lead time outlinedin your service agreement