1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges of a stone crusher plant often center on three critical areas:

Unscheduled Downtime: Bearing failures, component wear, and unexpected breakdowns halt your entire production line. Industry data indicates that for a midsized quarry, every hour of crusher downtime can result in over $1,000 in lost revenue and idle labor.
Inconsistent Output & Quality: Fluctuations in feed size or material hardness lead to variable final product gradation, failing to meet strict project specifications and resulting in rejected loads or costly reprocessing.
High Operational Expenditure: Soaring energy consumption from inefficient crushing chambers, combined with the frequent need for manual adjustment and highcost replacement parts for wear components, directly impacts your costperton metric.

Is your current crushing solution a constant source of reactive maintenance and financial leakage? What if you could implement a plant engineered from the outset for durability, efficiency, and predictable operation?

2. PRODUCT OVERVIEW: ODM STONE CRUSHER PLANT

Our ODM Stone Crusher Plant is a stationary or semimobile crushing circuit engineered for highvolume production of aggregates (05mm, 520mm, 2040mm) from primary rock types like granite, basalt, limestone, and river stone.

Operational Workflow:
1. Primary Crushing: Dump feed is reduced by a robust jaw crusher or gyratory crusher to a manageable size (typically <250mm).
2. Secondary & Tertiary Crushing: Material is conveyed to cone crushers or impact crushers for further size reduction and shaping to meet required specifications.
3. Screening & Classification: Vibrating screens separate crushed material into precise product fractions; oversize material is recirculated back to the appropriate crusher.
4. Material Handling: A network of conveyors efficiently moves material between stages and to final stockpiles.

Application Scope & Limitations:
Scope: Ideal for largescale quarry operations, infrastructure projects (road/highway construction), commercial concrete batching plants, and railway ballast production requiring consistent output from 150 to 800+ TPH.
Limitations: Not designed for processing highly abrasive ores (e.g., taconite) without specific liner configurations. Maximum feed size is determined by the primary crusher model selected.

3. CORE FEATURES

Modular Frame Design | Technical Basis: Preengineered, bolttogether heavyduty steel structure | Operational Benefit: Reduces site installation time by up to 30% versus welded designs; allows for future plant reconfiguration or relocation | ROI Impact: Lower capital installation costs and preserved asset flexibility extend plant lifecycle value.

Intelligent Crushing Chamber Geometry | Technical Basis: CADoptimized liner profiles and kinematics based on feed material analysis | Operational Benefit: Maintains consistent cavity volume throughout the wear cycle for stable output gradation and reduced frequency of manual adjustment | ROI Impact: Improves product yield within spec by an estimated 812%, reducing waste.

Centralized Grease Lubrication System | Technical Basis: Automated, programmable lubrication unit with blockage detection | Operational Benefit: Ensures optimal bearing lubrication across all major crushers under all operating conditions; eliminates manual greasing errors and intervals | ROI Impact: Field data shows a correlated 40% reduction in premature bearing failures, directly lowering parts costs and downtime.

PLCBased Process Control & Monitoring | Technical Basis: Industrial programmable logic controller with humanmachine interface (HMI) displaying amperage, pressure, temperature | Operational Benefit: Operators can monitor plant health in realtime; automated safety interlocks prevent catastrophic damage from tramp metal or overloads | ROI Impact: Enables predictive maintenance scheduling and protects major components from avoidable failure.

HighStrength AbrasionResistant Steel Components | Technical Basis: Use of AR400/500 steel in hoppers, chutes, and skirting at highwear points | Operational Benefit: Significantly extends service life in highabrasion transfer zones compared to mild steel; reduces frequency of patching and replacement | ROI Impact: Lowers longterm maintenance material costs and associated labor.

Tier4 Final / EU Stage V DieselElectric Option | Technical Basis: Diesel generator set powering allelectric drives on conveyors and screens | Operational Benefit: Provides full operational mobility without reliance on grid power; meets global emissions standards for flexible deployment | ROI Impact: Eliminates costly grid connection in remote sites while maintaining environmental compliance.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our ODM Stone Crusher Plant Solution | Documented Advantage |
| : | : | : | : |
| Overall Mechanical Availability (Annual) | 90 92% | >95% Target Design Standard| +3% to +5% Improvement |
| Energy Consumption per Ton Processed (kWh/t) Varies by rock type. Baseline = Limestone. Industry average derived from published case studies.| ~0.8 1.0 kWh/t| Optimized drive packages aim for ~0.7 0.9 kWh/t| Up to ~12% Reduction |
| Wear Life of Primary Jaw Liners (Abrasive Granite) Mn18Cr2 standard castings.| ~120,000 tons| Premium Mn22Cr2 optional liners target ~150,000 tons| +25% Improvement Available |
| Mean Time Between Failure (MTBF) Major Drives & Bearings Based on historical service data across comparable installations.| ~4,500 hours| Design targets >6,000 hours through superior sealing/lubrication systems.| +33% Improvement Target |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 TPH to 800+ TPH nominal capacity.
Power Requirements: Total connected load typically between 400kW 1200kW depending on configuration. Options include direct grid connection (380V/50Hz or 480V/60Hz) or integrated dieselelectric power pack.
Material Specifications: Primary structures fabricated from Q345B steel; highwear areas utilize AR450 abrasionresistant steel liners; crusher frames are highgrade cast steel or fabricated alloy steel.
Physical Dimensions (Example Configuration): A typical threestage plant footprint may approximate 65m (L) x 45m (W) x 18m (H). Modular design allows adaptation to site constraints.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with optional coldweather or dustsuppression packages available.

6. APPLICATION SCENARIOS

Highway Construction Project – Remote Location

Challenge: A contractor needed consistent Class I & II aggregates for a new highway section with no local grid power access. High mobilization/demobilization speed was critical due to tight project timelines.
Solution: Implementation of a semimobile ODM Stone Crusher Plant with integrated Tier4 Final diesel power pack and three crushing stages.
Results: The plant was commissioned within one week of arrival on site. It achieved an average output of 320 TPH meeting all gradation specs without reliance on external utilities.

Commercial Granite Quarry Expansion

Challenge: An existing quarry faced declining product quality consistency due to an aging secondary/tertiary circuit leading to excessive recirculating load (~40%) energy waste.
Solution: Replacement of the old tertiary cone crushers with new models featuring intelligent chamber geometry within an optimized ODM circuit layout.
Results: Recirculating load decreased to approximately 28%. This improved net throughput by 15% while reducing specific energy consumption by an estimated 9%, enhancing overall margin per ton processed.

7 COMMERCIAL CONSIDERATIONS

Our ODM Stone Crusher Plants are offered under clear commercial frameworks:

Pricing Tiers: Pricing scales according to capacity throughput design complexity:
Tier I Basic Configuration Standard duty primary jaw secondary cone basic screening
Tier II Enhanced Configuration Heavy duty primary premium cone multi stage screening dust suppression
Tier III Custom Turnkey Solution Full electrical automation remote monitoring advanced environmental controls

Optional Features Premium wear liners automatic level sensors magnetic separators sound attenuation enclosures extended walkways service platforms

Service Packages Available:
Basic Warranty Coverage standard parts labor warranty period
Annual Maintenance Contract scheduled inspections preventive maintenance parts discounts
Full Service Agreement includes guaranteed availability performance metrics consumables management

Financing Options We work with international export credit agencies equipment finance partners offer competitive leasing rental purchase structures suit project cash flow requirements

8 FAQ

Q What level foundation preparation required?
A Detailed civil engineering drawings provided require stable compacted ground minimal concrete foundations modular design reduces concrete volume versus traditional plants

Q How does ensure compatibility existing equipment?
A Our engineering team conducts pre sale review proposed layout feed characteristics can adapt transfer points conveyor lengths integrate certain existing units like primary screens

Q What typical lead time delivery commissioning?
A For standard configurations lead time ranges months ex works Site commissioning supervised our engineers typically requires weeks depending complexity includes operator training

Q Are spare parts readily available internationally?
A We maintain global network certified warehouse partners provide genuine spare parts support Critical wear items commonly stocked ensure minimal logistics delay

Q Can operate extreme cold climates?
A Yes optional packages include heated lube oil systems cold start battery packages insulated piping enclosures critical components ensure reliable operation sub zero temperatures

Q What process guarantee product gradation?
A While final gradation depends feed material characteristics we provide performance guarantees overall throughput mechanical availability based agreed test protocols commissioning

Q Do offer financing large capital purchases?
A Yes we have established relationships several international finance institutions assist structuring purchase lease arrangements improve project economics