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Is Unplanned Downtime Eroding Your Quarry’s Bottom Line?

For every hour your primary crushing circuit is offline, you are losing an average of $15,000 to $50,000 in potential revenue, depending on tonnage and material value. Plant managers face a constant battle: balancing the pressure for higher throughput against the reality of premature wear on standardduty components. Engineering contractors are often forced to choose between tight project budgets and the longterm reliability of their fixed plant designs.

Are your current screening decks blinding too quickly with sticky material, forcing costly manual cleaning? Is your cone crusher consistently operating below its optimal chamber profile due to inconsistent feed? The operational gap between a standard machine and a processoptimized solution is where your margins disappear. How can you specify equipment that delivers guaranteed uptime without the premium price tag of a major global brand?

Product Overview: The Private Label Crushing And Screening Solution

This equipment line is designed for hightonnage aggregate production and hardrock mining applications. It operates as a closedcircuit system, processing feed material from 0800mm down to a final product of 040mm with precise gradation control.

Operational Workflow:
1. Primary Feed: Runofmine (ROM) material is fed into the heavyduty vibrating grizzly feeder, scalping out fines (150mm) before the jaw crusher.
2. Primary Crushing: The hydraulic jaw crusher reduces material to a 200mm product, utilizing a deep, symmetrical crushing chamber for maximum reduction ratio.
3. Screening & Separation: Material is conveyed to a multideck inclined screen. The top deck separates oversize (+80mm) for recirculation; the middle deck isolates a specific product fraction (e.g., 2040mm); the bottom deck produces a fine aggregate (e.g., 520mm).
4. Secondary/Tertiary Crushing: Oversize material is fed into a cone crusher or impact crusher, configured for closedside setting (CSS) of 2040mm.
5. Final Product Stockpiling: Conveyors with variable speed drives direct finished aggregates to designated stockpiles, minimizing segregation.

Application Scope: Ideal for granite, basalt, limestone, and river gravel. Limitations: Not recommended for primary crushing of extremely abrasive, highsilica content material (>90% SiO2) without specific wearresistant liner packages.

Core Features

HeavyDuty Grizzly Feeder | Technical Basis: Variable Eccentricity Drive | Operational Benefit: Eliminates material bridging and ensures consistent feed rate to the jaw crusher. | ROI Impact: Reduces feeder maintenance costs by 30% and prevents crusher chokeups.

Hydraulic Chamber Clearing System | Technical Basis: Nitrogenoveroil accumulator system | Operational Benefit: Your operators can clear a blockage in under 10 minutes without manual torching or digging. | ROI Impact: Recovers up to 4 hours of production per unplanned blockage event.

Modular Screen Deck Tensioning | Technical Basis: Quickrelease wedge system | Operational Benefit: Screen media changes are completed by a twoman crew in 45 minutes, versus 3 hours on standard bolted systems. | ROI Impact: Reduces changeover labor costs by 60% and increases screen availability.

Advanced Liner Profile Design | Technical Basis: Finite Element Analysis (FEA) optimized crushing chamber | Operational Benefit: Maintains a consistent product shape (cubicity) even as the manganese wears, extending liner life by 1520%. | ROI Impact: Lower cost per ton of finished product.

Integrated Dust Suppression System | Technical Basis: Internal water spray manifold with atomizing nozzles | Operational Benefit: Meets OSHA and local environmental dust regulations without external misting towers. | ROI Impact: Avoids potential fines and project delays related to environmental compliance.

PLCControlled Lubrication | Technical Basis: Positive displacement pump with flow monitoring | Operational Benefit: Automatically adjusts grease volume based on bearing temperature and load, preventing both under and overlubrication. | ROI Impact: Extends bearing life by an average of 2,000 operating hours.

Private Label Customization | Technical Basis: Whitelabel manufacturing with your branding | Operational Benefit: You get a factorydirect machine with your company’s name and warranty, building brand equity with your endusers. | ROI Impact: Increases your perceived market value and customer loyalty without R&D investment.

Competitive Advantages

| Performance Metric | Industry Standard (Major OEM) | Private Label Solution | Advantage (% Improvement) |
| : | : | : | : |
| Uptime (Annual) | 9294% | 9698% | +4% (Field data from 12month trials) |
| Cost per Ton (Wear Parts) | $0.18 $0.25 | $0.14 $0.20 | 20% (Based on standard manganese) |
| Screen Changeover Time | 3 hours (2person crew) | 1.5 hours (2person crew) | 50% |
| Initial Capital Cost (CAPEX) | Baseline (100%) | 7080% of Baseline | 20% to 30% |
| Lead Time (Custom Order) | 1620 weeks | 812 weeks | 40% |
| Hydraulic System Complexity | High (multiple pumps) | Medium (single pump, priority valve) | 35% (Reduced failure points) |

Technical Specifications (Model: PLCS450)

• Capacity Rating: 350450 tonnes per hour (TPH) depending on feed material and closedside setting.
• Power Requirements: 350450 kW total installed power (Jaw: 160kW, Cone: 220kW, Screens/Conveyors: 70kW). Voltage: 380V/50Hz or 480V/60Hz (customizable).
• Material Specifications: Main frame fabricated from S355J2+N structural steel. Wear liners: 18% Manganese (Mn18Cr2) as standard; optional 22% Manganese (Mn22Cr2) for highabrasion applications.
• Physical Dimensions: Transport Length: 18m, Width: 3.2m, Height: 4.5m. Operating Weight: Approx. 85 tonnes.
• Environmental Operating Range: 20°C to +45°C. Hydraulic oil viscosity grade: ISO VG 46 (standard), ISO VG 68 (high ambient temp). Optional coldstart package for 30°C operation.

Application Scenarios

Hard Rock Quarry (Granite) | Challenge: High silica content (75%) was causing excessive wear on standard blow bars, requiring weekly replacement. | Solution: Implemented the Private Label crushing and screening plant with a heavyduty jaw/cone configuration and Mn22Cr2 liners. | Results: Wear part life increased from 40 hours to 110 hours. Cost per ton dropped by 28%. Plant availability rose to 97%.

River Gravel Processing | Challenge: The client needed to produce a specific 1020mm washed aggregate for a major infrastructure project but faced severe blinding on the screen decks due to clay content. | Solution: Installed the modular screening unit with polyurethane screen media and the integrated dust suppression system. | Results: Screen blinding was eliminated. The plant consistently produced 400 TPH of spec material. The client met the project deadline without penalty.

Mobile Contractor (Limestone) | Challenge: The contractor needed a highcapacity plant that could be relocated every 68 weeks with minimal setup time. | Solution: Supplied the private label plant on a skidmounted chassis with quickconnect electrical and hydraulic couplings. | Results: Setup time was reduced from 5 days to 2 days. The plant achieved 98% uptime over a 12month contract, significantly outperforming the contractor’s previous fleet.

Commercial Considerations

• Equipment Pricing Tiers:

Standard Package (PLCS450): $1,200,000 $1,500,000 (Includes jaw, cone, screen, conveyors, basic PLC).
Premium Package (PLCS450P): $1,600,000 $1,900,000 (Includes Premium Package features + advanced automation, remote monitoring, and Mn22Cr2 liners).

• Optional Features:

Remote telemetry module: $15,000
Coldstart hydraulic package: $8,500
Extended warranty (3 years/10,000 hours): $45,000

• Service Packages:

Basic: 1year warranty, 2 site visits for commissioning.
Pro: 2year warranty, 4 site visits, annual performance audit.
Elite: 3year warranty, 6 site visits, guaranteed uptime clause (98%).

• Financing Options: Direct factory financing available for qualified buyers. Terms: 10% down, 3660 month terms. Operating lease options also available.

FAQ

1. What is the typical lead time for a private label crushing and screening plant?
Standard lead time is 1012 weeks from order confirmation. Custom configurations (e.g., specific motor voltages, unique conveyor lengths) may extend this to 1416 weeks.

2. Can I use my own brand name and paint color on the equipment?
Yes. As a private label manufacturer, we apply your specified paint (RAL code) and install your brand decals. We do not place our own branding on the visible exterior.

3. How does the warranty work if I am an international buyer?
We offer a standard 12month warranty from the date of commissioning or 18 months from the date of shipment, whichever comes first. We provide remote technical support and can dispatch a service engineer within 72 hours for critical failures.

4. What is the expected lifespan of the manganese wear parts?
This depends entirely on feed material. For mediumhard limestone (UCS 100150 MPa), expect 8,00012,000 hours. For hard granite (UCS 200250 MPa), expect 4,0006,000 hours. We provide a costperton guarantee based on your material analysis.

5. Is the equipment CE or ASME certified?
Yes. All equipment is manufactured to CE standards (EU) and can be certified to ASME standards (USA) upon request. We also provide full documentation for local regulatory approvals.

6. Can this plant be integrated into an existing fixed or mobile setup?
Yes. The modular design allows for integration. We provide all interface drawings (AutoCAD) and can supply transition conveyors to match your existing infrastructure.

7. What is the total cost of ownership (TCO) compared to a major brand?
Based on a 5year lifecycle analysis, our TCO is typically 1520% lower. This is driven by lower initial CAPEX, reduced lead times, and lower cost of wear parts. Maintenance complexity is also reduced due to a simpler hydraulic system.