H1: ODM Stationary Crushing & Screening Plant: Engineered for Maximum Uptime and Tonnage

1. Addressing Your Core Operational Challenges in Aggregate Production

Managing a fixed crushing site presents distinct, costly challenges. Downtime isn't just lost production; it's missed contracts and eroding margins. Are you facing:
Unplanned Stoppages: Bearing failures, crusher blockages, and conveyor issues can halt your entire line. Every hour of downtime can cost thousands in lost revenue and idle labor.
Inconsistent Final Product: Fluctuations in feed material or improper calibration lead to offspec aggregate, resulting in product rejection, recrushing costs, and damaged client relationships.
High Maintenance Complexity: Disjointed equipment from multiple suppliers creates a spare parts nightmare and extends maintenance windows, straining your operational budget.
Inefficient Material Flow: Bottlenecks between crushing stages or screening units cap your plant's true capacity, forcing you to run longer hours at higher cost per ton.
Rising Operational Costs: Energyinefficient drives, excessive wear part consumption, and high manual labor for monitoring directly reduce your profitability per cubic meter.

The question is not just how to crush rock, but how to build a reliable, predictable production asset. The solution lies in a fully integrated system designed from the ground up for synchronized performance.

2. Product Overview: The Integrated Stationary Crushing & Screening Plant

The ODM Stationary Crushing & Screening Plant is a complete, hardwired processing circuit engineered for highvolume aggregate production in quarrying and mining applications. It transforms raw feed (0800mm) into precisely graded final products (e.g., 05mm sand, 520mm aggregate).

Operational Workflow:
1. Primary Feeding & Crushing: Dump trucks feed a vibrating grizzly feeder which removes fines and directs oversize to a robust primary jaw crusher for initial size reduction.
2. Intermediate Processing & Screening: Crushed material is conveyed to a secondary cone crusher for further reduction. Output is then routed to a multideck vibrating screen for classification.
3. Product Sorting & Stockpiling: Onspec material from each screen deck is conveyed to designated stockpiles. Oversize is recirculated back to the appropriate crusher in a closedcircuit loop.

Application Scope: Ideal for hightonnage production of aggregates for concrete, asphalt, and road base. Suitable for processing granite, basalt, limestone, and other abrasive ores.

Limitations: This is a fixedinstallation solution requiring foundational concrete works and grid power connection. It is not designed for frequent relocation.

3. Core Features: Engineering Meets Operational ROI

Modular Structural Frame | Technical Basis: Prefabricated, hightensile steel sections with machined connection points | Operational Benefit: Enables faster, more precise onsite installation with reduced crane time and foundation work | ROI Impact: Cuts installation timeline by up to 30%, reducing timetorevenue.

Centralized PLC Control System | Technical Basis: Programmable Logic Controller with humanmachine interface (HMI) panel | Operational Benefit: Allows singleoperator monitoring and control of the entire flow from feeder to final conveyor; provides diagnostic alerts | ROI Impact: Reduces labor requirements by approximately 1 FTE per shift while improving response time to anomalies.

HeavyDuty Vibrating Screen with QuickDeck Change | Technical Basis: Rubbermounted screen box with tensioned wedgewire or polyurethane panels | Operational Benefit: Minimizes vibration transfer to structure; allows screen media replacement in hours vs. days | ROI Impact: Increases annual availability by ~2% and reduces maintenance labor costs.

Crusher Cavity Optimization | Technical Basis: Computeraided design of crushing chamber geometry matched to expected feed material | Operational Benefit: Maximizes reduction ratio per pass, improves product shape (cubicity), and promotes even wear liner utilization | ROI Impact: Boosts throughput by 515% while extending wear part life cycles.

Dust Suppression & Containment System | Technical Basis: Strategically placed spray nozzles at transfer points with encapsulation skirts | Operational Benefit: Maintains regulatory compliance for particulate emissions; protects bearings and motors from dust ingress | ROI Impact: Avoids regulatory fines and reduces premature bearing failures by an estimated 40%.

Layered Walkways & Maintenance Platforms | Technical Basis: Full perimeter access with safety handrails integrated into the plant design | Operational Benefit: Enables safe visual inspections, routine greasing, and component servicing without specialized scaffolding | ROI Impact: Promotes proactive maintenance culture; reduces risk of safety incidents and associated downtime/costs.

4. Competitive Advantages: Quantifiable Performance Gains

| Performance Metric | Industry Standard Benchmark | ODM Stationary Plant Solution | Documented Advantage |
| : | : | : | : |
| Plant Availability (Scheduled Runtime) | 9092% | 9496%| +4% Improvement |
| Energy Consumption per Ton Processed| Varies by rock type| Optimized motor loads & efficient drives| Up to 12% Reduction |
| Wear Part Cost per Metric Ton| $0.85 $1.10 USD| Matched chamber design & alloy selection| 1520% Reduction |
| Installation & Commissioning Time| 810 Weeks (from foundation)| Modular frame & preassembled units| ~30% Faster (67 Weeks)|
| Required Operating Labor per Shift| 34 Personnel| Centralized PLC control system| Reduced by 1 Operator |

5. Technical Specifications

Design Capacity Range: 200 800 TPH (configurable based on model).
Primary Power Requirement: 400V/50Hz or 480V/60Hz; Total Installed Power: 350kW 800kW.
Key Material Specifications:
Crusher Liners: Manganese Steel (14%,18%,22%) or Chrome Iron Alloy options.
Screen Decks:Tensioned Polyurethane or HighCarbon Steel Wire Mesh.
Conveyor Belting:Synthetic Fabric Ply (EP630/3) with minimum 12mm top cover.
Structural Steel:S355JR grade with hotdip galvanized finish on walkways.
Typical Physical Footprint (for a 350TPH plant): ~35m (L) x 22m (W) x 15m (H).
Environmental Operating Range: Ambient temperature 20°C to +45°C; dust emission levels compliant with <10mg/Nm³ standards when used with suppression system.

6. Application Scenarios

Granite Quarry Expansion Project

Challenge:A quarry needed to increase output by over 60% but had limited space for plant expansion within their existing lease boundary.Solution:A compact,OEMdesigned threestage crushing circuit was installed,fitting into the footprint of an older twostage plant.The design included a large primary jaw crusher followed by two secondary cone crushers in parallel configuration feeding shared screens.This allowed higher throughput without increasing land use.The centralized control system was integrated into their existing site office via fiber optic cable.The new layout reduced internal haulage distances significantly.Retrofitted spray systems kept dust under control during blasting operations near residential areas.Finally,the modular construction allowed commissioning during planned seasonal shutdown minimizing disruption.Financing was secured through an equipment lease agreement preserving capital for other site improvements.Regular service visits ensured optimal performance throughout the warranty period leading them purchase an extended coverage plan.This holistic approach transformed their operational constraints into competitive advantage securing several large infrastructure contracts previously out reach due capacity limitations

Limestone Processing for Cement Plant Feed

Challenge:A cement producer required consistent 25mm feed for their raw mill,but variations in quarry moisture content caused frequent clogging in their existing impact crusher.Solution:The implementation featured a primary jaw crusher followed by a heavyduty cone crusher equipped with automated setting regulation.Air cannons were installed at key hopper points,and conveyor skirts were extended.The PLC system was programmed to adjust feeder speed based on crusher motor load.Field data after six months showed clogging events reduced by over95%.Product consistency improved dramatically meeting the 25mm spec99.%of the time.This reliability allowed the cement kiln department optimize their own processes knowing raw material supply would be uninterrupted

Urban Infrastructure Project Recycling

Challenge:A major road construction project mandated onsite recycling of demolished concrete to reduce truck traffic environmental impact but faced strict noise dust regulations tight urban site.Solution:A semimobile configuration was deployed featuring extensive acoustic enclosures around all major noise sources like crushers screens fully enclosed conveyors waterbased dust suppression systems every transfer point.The plant processed over500000tons recycled concrete aggregate meeting all stringent local environmental standards avoiding thousands truck movements city center

Commercial Considerations

Pricing is structured around plant capacity,customization level,and chosen component brands(e.g.,crusher motor manufacturer).We offer three primary tiers:

1.Basic Configuration Tier:Covers core functionality standard components proven reliability suitable budgetconscious operations seeking essential performance.Pricing typically ranges from$750000to$1million USD depending capacity

2.Performance Tier(Recommended):Includes features like centralized PLC automation premium wear liners enhanced dust suppression walkways platforms.Pricing typically ranges from$ million$ million USD

3.Turnkey Premium Tier:Fully customized solution including advanced predictive monitoring sensors extended warranty comprehensive operator training package civil engineering drawings support.Pricing determined specific project scope

Optional Features Upgrades:
Advanced vibration monitoring sensors critical bearings
Automated lubrication systems
Overband magnetic separator ferrous metal removal
Additional finished product conveyor stackers
Spare parts starter kit

Service Support Packages:
Standard Warranty months parts labor excluding wear items
Extended Coverage Plans years available purchase
Annual Maintenance Contracts include scheduled inspections priority technical support discounted spare parts
OnDemand Field Service Technician dispatch available global network partners

Financing Options:
We work accredited financial partners offer:
Equipment leasing structures preserve working capital
Term loans competitive rates project financing
RentaltoOwn programs lower initial commitment

FAQ Section

What if my feed material hardness changes frequently?
Our cone crushers recommended Performance Tier feature hydraulic adjustment CSS clearing allow quick adaptation different rock characteristics without stopping process ensuring consistent output quality varying conditions

How does this integrate existing equipment like my primary excavator loaders?
Plants designed flexible feeding arrangements accommodate different loading methods We provide interface specifications hopper heights capacities ensure compatibility your current loading fleet minimizing integration issues

What typical lead time delivery commissioning?
For standard configurations lead time typically weeks exworks following deposit receipt Site commissioning supervised our engineers requires approximately weeks depending complexity local readiness

Are spare parts readily available globally?
Yes maintain strategic inventory critical components partner global logistics providers ensure expedited shipping Additionally provide detailed part numbers crossreferences equivalent items facilitate local sourcing noncritical parts where appropriate

Do you offer operator training?
Yes comprehensive training included Turnkey Tier optional others covers normal operation routine maintenance troubleshooting safety procedures Training conducted both our facility yours ensure competence confidence your team