1. PAINPOINT DRIVEN OPENING

Managing a private label quarry operation in Lagos presents distinct challenges that directly impact your bottom line and market competitiveness. Are you grappling with inconsistent aggregate quality that leads to product rejection? Are production bottlenecks and frequent equipment downtime causing you to miss critical delivery windows for construction projects? Is the high operational cost of running aging, inefficient crushing and screening lines eroding your profit margins on every ton sold? The pressure to supply certified, specificationgrade aggregates for Lagos’s infrastructure boom demands a reliable, highoutput solution. How do you transform your site from a cost center into a consistent, profitable source of highdemand construction materials?

2. PRODUCT OVERVIEW

The Private Label Quarry Plant is a complete, modular crushing and screening system engineered for the production of specification aggregates under your own brand. This turnkey solution is designed for quarry owners aiming to control quality, maximize yield, and optimize operational costs.

Operational Workflow:
1. Primary Reduction: Raw feed from the quarry face is fed into a robust primary jaw crusher for initial size reduction.
2. Secondary/Tertiary Crushing: Material is then processed through a cone crusher or impact crusher circuit to achieve the desired cubicity and gradation.
3. Precision Screening: Multipledeck vibrating screens accurately separate crushed material into specified aggregate sizes (e.g., 3/4", 1/2", sharp sand, stone dust).
4. Stockpiling & Loading: Sized aggregates are conveyed to dedicated stockpiles for qualitycontrolled storage and direct loading onto trucks.

Application Scope: Ideal for establishing new private label quarries or retrofitting existing sites in granite, limestone, and other hard rock formations common in SouthWest Nigeria. This system is configured for the production of aggregates for concrete, asphalt, road base, and drainage applications.

Limitations: Not designed for soft rock or unconsolidated material mining without significant configuration changes. Site requires adequate space for plant layout and stockpiles.

3. CORE FEATURES

Modular Plant Design | Technical Basis: Bolttogether, skidmounted sections | Operational Benefit: Significantly reduces civil works and installation time onsite, enabling faster commissioning. | ROI Impact: Cuts project startup time by up to 40%, accelerating timetorevenue.

HighEfficiency Cone Crusher | Technical Basis: Hydroset system and optimized crushing chamber | Operational Benefit: Maintains consistent product gradation and shape with minimal manual adjustment, even as liner wear occurs. | ROI Impact: Improves yield of premiumgrade aggregates by an average of 15% and reduces waste.

MultiStage Screening Circuit | Technical Basis: Tripledeck, highfrequency vibrating screens with tensioned rubber decks | Operational Benefit: Provides precise separation of up to four product sizes simultaneously, ensuring strict adherence to NIS/BS standards. | ROI Impact: Eliminates costly reprocessing of offspec material and maximizes saleable product from each ton of feed.

Centralized PLC Control System | Technical Basis: Automated process control with touchscreen HMI | Operational Benefit: Allows operators to monitor and adjust the entire flow from a single station, optimizing throughput and identifying bottlenecks instantly. | ROI Impact: Reduces labor requirements per ton produced and minimizes human error in process control.

HeavyDuty Apron Feeder | Technical Basis: Overlapping manganese steel flights driven by rugged reduction gears | Operational Benefit: Provides consistent, regulated feed to the primary crusher under all load conditions, including sticky or wet material common in Lagos’s climate. | ROI Impact: Prevents crusher chokefeed events that cause downtime and protects downstream equipment from surge loads.

Dust Suppression System Integration| Technical Basis: Pressurized water spray nozzles at key transfer points| Operational Benefit: Actively controls fugitive dust at source, promoting a safer working environment and supporting compliance with environmental considerations.| ROI Impact: Mitigates operational delays due to environmental complaints and reduces wear on machinery from abrasive dust.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Setup) | Private Label Quarry Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tonnage per ManHour| 810 Tons/Hour/Operator| 1416 Tons/Hour/Operator| +60% Labor Efficiency |
| Product Yield (Spec Material)| ~7580% of total feed| Consistently 8892% of total feed| +15% Saleable Product |
| Mean Time Between Failure (Crushing Circuit)| ~450 Operating Hours| >700 Operating Hours (documented)| +55% Reliability |
| Energy Consumption per Ton| Baseline (100%)| Measured at approx. 82% of baseline| 18% Power Cost |
| Plant Reconfiguration Time| Weeks for major changes| Days due to modular design & PLC presets| 70% Downtime |

5. TECHNICAL SPECIFICATIONS

Designed Capacity Range: 150 400 tons per hour (configurable based on feed material and final product mix).
Primary Crusher: Jaw Crusher, Feed Opening up to 1200mm x 800mm.
Secondary Crusher: Hydraulic Cone Crusher with multiple chamber options.
Screening Units: (2) Tripledeck Vibrating Screens; Screen area of 18m² each.
Power Requirements: Total installed power approximately 450 650 kW; configured for stable grid or heavyduty generator set operation.
Key Material Specifications: Highwear components (liners, aprons) use AR400 steel or OEMmanufactured manganese; structural frames are heavygauge carbon steel.
Physical Dimensions (Modular Units): Individual modules designed for standard transport; max module dimensions ~12m L x 3m W x 4m H.
Environmental Operating Range: Designed for ambient temperatures of 15°C to 45°C; humidity up to 95%; dust suppression rated for effective operation.

6. APPLICATION SCENARIOS

Concrete Aggregate Production Challenge:

A Lagosbased quarry supplying readymix plants faced frequent rejection of its coarse aggregate due to poor cubicity and excessive flakiness index (<15), compromising concrete strength specifications.

Solution:

Implementation of a Private Label Quarry Plant centered on a highefficiency cone crusher with a cubicalshaped crushing chamber profile was implemented alongside precise screening decks calibrated specifically for coarse aggregate sizing bands required by major batching plants operating within Lekki Free Zone environs etcetera

Results:

Aggregate cubicity improved consistently above >85%, meeting all EN & BS standards while eliminating product rejections entirely within six months postinstallation thereby securing longterm supply contracts worth over ₦500 million annually

Road Base & Asphalt Chipping Production Challenge:

An established quarry near Ibadan expressway struggled with low yield (<70%)of premium asphalt chippings(10mm &14mm)and inconsistent gradation leading them unable compete effectively against imported alternatives despite lower logistical costs

Solution:

Deployment focused heavily upon multistage screening circuit featuring specialized screen media combined tertiary impact crusher finetuning particle shape resulting dualflow system capable producing both superior road base materials alongside specification chippings simultaneously

Results:

Yield increased dramatically reaching averages around ninety percent(90%)for chipping products allowing company successfully bid supplying major federal highway rehabilitation projects across Ogun State region increasing annual revenue forty percent yearoveryear

Commercial Considerations

Equipment pricing tiers vary based on capacity configuration starting at approximately ₦180 million Naira ($120k USD equivalent)for basic setup reaching upwards ₦700 million($465k USD equivalent)for fully automated highcapacity systems inclusive auxiliary equipment like excavators etcetera Optional features include advanced metal detection systems automated lubrication packages remote monitoring telematics Service packages offered comprise scheduled maintenance plans critical spare parts kits comprehensive operator training programs Financing options available through partner institutions include leasepurchase agreements structured over three five years terms tailored cash flow needs Nigerian businesses

FAQ

Q What existing infrastructure needed install this plant?
A You require suitable land area approximately one hectare accessible heavy trucks reliable electrical connection threephase supply water source dust suppression Minimal civil works needed due modular nature foundations simple concrete pads

Q How quickly can become operational after delivery?
A With all preparations complete typical commissioning period ranges between four six weeks depending site conditions complexity chosen configuration includes thorough operator training period

Q Can this system produce both sharp sand plaster sand?
A Yes specific configurations incorporate VSI(Vertical Shaft Impactor)crusher sand manufacturing module producing precisely graded manufactured sand alternative natural river sand meeting strict concrete specifications

Q What ongoing technical support available?
A Comprehensive service network includes local technical team Lagos supported regional depot stocked common wear parts offering scheduled maintenance emergency breakdown response within agreed service level agreements(SLAs)

Q Are there financing options available Nigerian companies?
A Yes we collaborate several financial institutions provide asset financing solutions including leasepurchase structures help manage capital expenditure improve cash flow typically requiring thirty percent down payment balance spread across term

Q How ensure plant remains efficient over time?
A Our recommended scheduled maintenance plan includes regular wear part inspection lubrication system checks performance data analysis via PLC telematics allowing proactive maintenance preventing unscheduled stoppages