1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unplanned Downtime: Frequent breakdowns of underengineered crushers halt your entire material processing chain, costing thousands per hour in lost production and labor.
Excessive Wear & Maintenance Costs: The abrasive nature of slag rapidly degrades standard crushing components, leading to unsustainable spending on replacement parts and maintenance labor.
Inconsistent Output & Product Quality: An unreliable crusher produces poorly graded aggregate, creating downstream handling issues and reducing the market value of your final product.
High Operational Complexity: Equipment that requires constant adjustment and skilled monitoring increases the risk of human error and diverts your team from core tasks.

What if your slag handling system could be a source of reliability and profit, rather than a recurring cost center? The solution lies in specifying equipment engineered explicitly for the task.

2. PRODUCT OVERVIEW

A Private Label Slag Crusher Plant is a turnkey, heavyduty processing system designed to reduce slag from blast furnaces, steel mills, or foundries into a specified, reusable aggregate. Engineered for private branding by equipment distributors or large contractors, it provides a branded, highperformance solution without inhouse manufacturing.

Operational Workflow:
1. Feed & PreScreening: Slag is fed via loader or conveyor into an integrated prescreening module to remove fine fractions and bypass material.
2. Primary Size Reduction: Oversize material is directed to the core crusher—typically a jaw or impact crusher built with specialized alloys—for initial breakage.
3. Secondary Crushing & Classification: Crushed material may pass through a secondary cone or impact crusher for further refinement, then to final sizing screens.
4. Stockpiling: Correctly sized aggregate is conveyed to designated stockpiles for storage or direct loading.

Application Scope: Processing blast furnace slag (BFS), steel slag, and nonferrous slags into construction aggregate for road base, cement additive, or rail ballast.
Key Limitation: Not designed for primary mining of virgin rock or for processing materials with extreme moisture content without preconditioning.

3. CORE FEATURES

HeavyDuty Rotor & Chamber | Technical Basis: Highinertia rotor design with optimal impact angles | Operational Benefit: Sustains crushing force against irregular, abrasive slag chunks with less vibration and wear | ROI Impact: Reduces stressrelated failures by an estimated 40%, lowering lifetime repair costs.

AbrasionResistant Liner System | Technical Basis: Interchangeable liners made from chromium carbide or AR400+ steel | Operational Benefit: Provides 34x the service life of standard manganese steel in highabrasion zones | ROI Impact: Extends liner change intervals, cutting parts inventory costs and planned downtime by up to 30%.

Hydraulic Adjustment & Clearing | Technical Basis: Integrated hydraulic cylinders for crusher gap setting and tramp iron release | Operational Benefit: Allows operators to adjust product size or clear blockages in minutes without manual intervention | ROI Impact: Minimizes unplanned stoppages; field data shows a 90% reduction in blockagerelated downtime.

PLCBased Control & Monitoring | Technical Basis: Centralized programmable logic controller with touchscreen HMI | Operational Benefit: Enables precise control over feed rates, crusher load, and conveyor sequencing for optimal throughput | ROI Impact: Improves overall plant efficiency by 1525% through automated coordination and fault diagnostics.

Modular SkidMounted Design | Technical Basis: Preassembled modules on heavyduty structural skids | Operational Benefit: Reduces onsite civil works and installation time by up to 60% compared to fixed foundation plants | ROI Impact: Lowers total installed cost and accelerates timetorevenue following purchase.

Integrated Dust Suppression | Technical Basis: Strategically placed spray nozzles with solenoid control tied to crusher operation | Operational Benefit: Effectively controls dust at primary transfer points, improving site safety and environmental compliance | ROI Impact: Mitigates risk of regulatory fines and reduces cleanup labor.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Private Label Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life in Slag Service| Standard Manganese Steel (Approx. 80k MT)| Specialized Alloy Liners (Approx. 250k MT) | +212% |
| Tonnage Between Unplanned Stops| Variable; frequent blockages require clearing| Automated clearing & robust design enable consistent throughput| +70% Reliability |
| Power Consumption per Ton| Less efficient drives & motor sizing| Optimized drive train with loadsensing hydraulics| 18% Energy Use |
| Installation & Commissioning Time| 46 weeks for discrete component assembly| 1014 days for skidmounted module connection| 65% Time |
| Final Product Consistency (Gradation)| +/ 15% variation due to wear & manual adjustment| +/ 5% variation via hydraulic adjustment & process control| +66% Consistency |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 to over 600 metric tons per hour.
Primary Crusher Options: Jaw Crusher (for slabby slag) or Horizontal Shaft Impactor (for cubical product), sizes from 500x750mm up to 1500x2000mm.
Power Requirements: Total installed plant power typically ranges from 150 kW to 450 kW, dependent on configuration. Requires stable industrial threephase supply.
Key Material Specifications: Mainframe construction from S355JR structural steel; Wear components in AR400/AR500 or equivalent chromium iron alloys; Conveyor belts rated for MSHA/ISO abrasion resistance.
Physical Dimensions (Example Configuration): Primary crushing module approx. L12m x W4m x H5m. Fully modular design allows flexible layout adaptation.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system effective up to 80% relative humidity.

6. APPLICATION SCENARIOS

Steel Mill ByProduct Recovery | Challenge: A major steel producer faced escalating landfill costs for processed slag and needed to create a saleable aggregate product internally. Their existing equipment suffered excessive wear and low availability.| Solution: Implementation of a turnkey Private Label Slag Crusher Plant configured with a primary impactor and secondary cone crusher for precise cubical shaping.| Results: The plant achieved 95% operational availability within six months. Landfill costs were eliminated, replaced by revenue from aggregate sales realizing an estimated payback period of under three years.

Construction Materials Contractor Diversification | Challenge: A large civil works contractor sought vertical integration by processing purchased slag into road base material but lacked the technical expertise to spec individual components.| Solution: Procurement of a preengineered Private Label Slag Crusher Plant under their own brand name, including full operator training packages.| Results: Gained complete control over feedstock quality and cost structure for major projects. Internal project costs reduced by an average of 18%, while creating a new revenue stream from external aggregate sales.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Capital cost varies significantly based on capacity and complexity.
Base Tier: Primary crushing only modules start at a lower investment point suitable for lowervolume processors.
Mid Tier: Complete twostage crushing/screening plants represent the most common configuration balance of output versus cost.
High Tier: Fully automated systems with advanced metal separation stages command premium pricing but deliver highestvalue end product.
Optional Features: Magnetic separator drums for ferrous recovery, tertiary crushing stages for sand manufacture, automated lubrication systems, remote monitoring telematics packages.
Service Packages: Extended warranties (beyond standard 12 months), guaranteed parts availability contracts (e.g., 48hour delivery), annual preventive maintenance inspections conducted by factorytrained technicians.
Financing Options: Available through partner institutions including equipment leasing structures (operational lease/finance lease), rentaltoown programs tailored for projectbased work

8.FAQ

1.Q What level of feedstock preparation is required before the slag enters the crusher?
A For optimal performanceand minimal wear,s lag should be prescreenedto remove fines (10mm)and free metals where possible.Feed size should generally not exceed80%of the crushe rfeed opening dimension.Magnetic separation before crushingis highly recommendedfor steel slag

2.Q How does this plant impact my overall site operational manpower requirements?
A The PLCcontrolleddesign centralizes operationsto oneor two personnel.The automationof feed sequencingand safety interlocks reduces the needfor manual coordinationbetween multiple machine operators

3.Q Are spare parts readily available given this is private label equipment?
A Yes.All core wear partsand mechanical componentsare sourcedfrom globally recognized tierone supplierswith established distribution networks ensuringavailability.Part numbersare standardizedfor easy identificationand ordering

4.Q What are typical installation requirementsin terms offoundationsand utilities?
A The skidmounteddesign requires only simpleconcrete padsor footingsfor levelling notthe deeppiers neededfor fixed plants.Besides electrical power you will needa reliable water sourceforthe dust suppression systemat approximately1020 litersper minute

5.Q Can the final product specificationbe changedafter installation?
A Yes withinthe performancerangeofthe installedcrushers.Hydraulic adjustmenton both jawand impactcrushers allows operatorso alterthe discharge settingto produce differentaggregate sizes typicallyin under fiveminutes

6.Q What financingstructuresare commonly usedfor this typeof capitalequipment purchase?
A Most commercial buyersutilizea combinationof solutionsincludingcapital expenditure(CAPEX) purchasewitha manufacturerbackedloan operatinglease(OPEX)for preservingcash flowor renta lprogramsfor shorttermproject needsSpecific termsdependon credit profileand application

7.Q How is performanceguaranteedprior topurchase?
A Reputable supplierswill provide detailedcomputerized flow simulationbasedonyour specificslag analysisand requiredoutput tonnageThis simulationdata backedby performanceguaranteesin the sales contractensures the plantmeetsyour definedproduction targets