1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges in material reduction often stem from inefficient primary crushing. Common pain points include:
Excessive Downtime for Maintenance: Frequent liner changes and unplanned repairs on your primary crusher halt your entire processing line, costing thousands per hour in lost production.
Inconsistent Feed Size Reduction: Variable feed material causes chokefeeding or erratic performance, leading to downstream bottlenecks in your secondary and tertiary circuits.
High Operational Costs: Soaring energy consumption per ton of processed material and premature wear part failure directly impact your bottomline profitability.
Limited Flexibility & Scalability: A fixed crushing solution cannot adapt to changing feed materials or increased production targets without significant capital reinvestment.

Is your primary crushing station the bottleneck in your operation? What would a 1520% reduction in costperton mean for your annual budget? The solution lies in specifying a highperformance, reliable primary crushing station engineered for maximum uptime and efficiency.

2. PRODUCT OVERVIEW: PRIMARY CRUSHING STATION

A Primary Crushing Station is a complete, semifixed or modular system designed for the first stage of size reduction in quarrying, mining, and largescale construction applications. Its function is to accept runofmine or blasted feed material (up to 1000mm+) and reduce it to a conveyable size for transport to downstream processing.

Operational Workflow:
1. Feed & PreScreening: Dump trucks deposit material into a robust vibrating grizzly feeder (VGF).
2. Primary Reduction: The VGF scalps fines and directs oversize material into a highcapacity jaw crusher or gyratory crusher for initial compression breaking.
3. Material Handling: Crushed product is discharged onto a main conveyor belt system for transport to the next stage of processing.

Application Scope: Ideal for hightonnage hard rock (granite, basalt), abrasive ores, and recycled concrete operations requiring throughput from 500 to over 2,500 tph.

Limitations: Not suitable as a standalone solution where final product specification is required; must be integrated with secondary/tertiary crushing and screening circuits. Site requires adequate space for setup and feed access.

3. CORE FEATURES

Patented Quarry Jaw Design | Technical Basis: Optimized kinematics & reinforced chamber geometry | Operational Benefit: Achieves higher reduction ratios with lower wear rates, minimizing frequency of liner changes | ROI Impact: Reduces wear part inventory costs by an estimated 18% and increases crusher availability

HeavyDuty Modular Base Frame | Technical Basis: Preengineered, bolttogether substructure with integral walkways | Operational Benefit: Enables faster site installation and future relocation without heavy fabrication work | ROI Impact: Cuts installation time by up to 40%, accelerating timetoproduction

Intelligent Variable Speed Feeder Control | Technical Basis: PLCdriven VGF with loadsensing technology | Operational Benefit: Automatically regulates feed rate to prevent crusher overload (choke) or underutilization (starve) | ROI Impact: Optimizes power draw, improving energy efficiency by up to 12% and maximizing throughput

Integrated Dust Suppression System | Technical Basis: Strategically placed nozzle arrays with solenoid control tied to crusher operation | Operational Benefit: Actively suppresses dust at key transfer points only when needed, conserving water | ROI Impact: Ensures regulatory compliance while reducing water consumption by approximately 30%

Centralized Greasing & Lube Station | Technical Basis: Singlepoint connection for automated lubrication of all major bearings | Operational Benefit: Allows safe, routine maintenance from one location in under 15 minutes | ROI Impact: Enhances bearing life by ensuring consistent lubrication, preventing costly failures

HighStrength Discharge Conveyor | Technical Basis: Channel frame design with impact bars at loading zone | Operational Benefit: Withstands continuous heavy loads and direct impact from crushed discharge | ROI Impact: Reduces belt damage and spillage, lowering conveyor maintenance costs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Primary Crushing Station Solution | Documented Advantage |
| : | : | : | : |
| Availability (Scheduled Runtime) | 8892% | 95%+| +47% Improvement |
| Cost per Ton (Wear Parts) | Baseline (100%)| 85%| 15% Reduction |
| Installation & Commissioning Time| 810 Weeks| 56 Weeks| ~40% Faster Deployment |
| Energy Consumption (kWh/ton)| Varies by rock type| Up to 12% Lower| Verified by field telemetry |
| Mean Time Between Failure (MTBF)| ~1,200 hours| >1,600 hours| +33% Reliability Increase |

5. TECHNICAL SPECIFICATIONS

Crusher Type: HeavyDuty Single Toggle Jaw Crusher
Feed Opening: 1,400mm x 1,200mm (55" x 47")
Maximum Feed Size: 1,000mm (39")
Closed Side Setting (CSS) Range: 150mm 300mm (6" 12")
Capacity Range: Up to 900 1,200 tph (dependent on material density & CSS)
Drive Power: Tier IV Final / Stage V compliant dieselelectric or direct electric drive options; 200 kW main crusher motor.
Structural Fabrication: Hightensile steel plate with abrasionresistant liners at critical wear points.
Station Footprint (L x W): Approximately 28m x 8m (92' x 26').
Operating Temperature Range: 25°C to +45°C (13°F to +113°F) with appropriate fluid specifications.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A granite producer needed to increase plant throughput by 35% but was constrained by an aging primary crusher causing 10 hours of weekly unplanned downtime.
Solution Implementation of our modular Primary Crushing Station with the patented jaw design and intelligent feeder control.
Results Station commissioned in 5 weeks. Achieved sustained throughput of 950 tph with availability exceeding 96%. Costperton reduced by 18%, paying back the investment in under 14 months.

LargeScale Infrastructure Development

Challenge A civil engineering contractor required a temporary highvolume crushing solution for processing excavated basalt on a major highway project, with strict dust control regulations.
Solution Deployment of a mobileprimarycrusherconfigured station with integrated dust suppression and quickrelocation capability.
Results The station processed over 2 million tons of material onsite across three different project phases. Dust emissions remained within compliance limits without slowing production, eliminating offsite hauling costs.

7. COMMERCIAL CONSIDERATIONS

Our Primary Crushing Stations are offered in three capabilitybased tiers:
Essential Tier: Highreliability core system ideal for consistent feed materials. Base pricing structured around required throughput capacity.
Performance Tier: Includes advanced features like intelligent feeder control, automated lubrication,and enhanced dust suppression for operations targeting optimal costperton.
Elite Tier: Fully customized stations with premium components,surge capacity design,and predictive maintenance telemetry integration for megaprojects.

Optional features include onboard power generation sets,magnet systems for tramp metal removal,and heated operator stations.Service packages range from basic commissioning support to comprehensive Planned Maintenance Agreements covering parts,labor,and scheduled inspections.Financing options include capital lease agreements,tailored rentaltoown structures,and projectbased financing through accredited partners.

8. FAQ

Q1 Is this Primary Crushing Station compatible with my existing secondary plant?
A Yes.The discharge conveyor speed heightand load capacity are engineered during specificationto match your downstream receiving hopper or screen feed conveyor ensuring seamless integration.

Q2 What is the expected operational impact during liner changes?
A Our jaw design features hydraulic setting adjustmentand reversible liners.Field data shows liner changeout can be completed typically within one standard shift minimizing production loss comparedto older designs requiring longer downtime

Q3 Are there financing options available that alignwith our project cash flow?
A Yes.We offer several commercial structures including operating leases that preserve capitaland milestonebased payment plans tiedto commissioningand performance verification

Q4 How does the intelligent feeder control handle highly variable feed material?
A The PLC system monitors crusher power drawin realtime automatically slowingor speedingthe feeder tomaintain optimal chamber loading This protects the crusherfrom tramp metal eventsand mitigates the effectsof size variation

Q5 What trainingis providedfor our maintenance crew?
A Comprehensive trainingis included covering daily inspections routine maintenance proceduresand wear part replacement protocols Documentation includes detailed manualsand troubleshooting guides