1. PAINPOINT DRIVEN OPENING

Are you managing a highvolume aggregate production site and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300 tph stone crushing plant is a critical asset, yet standard configurations often introduce costly inefficiencies. Common challenges include:
Unscheduled Downtime: Component failures in harsh environments lead to production halts, costing thousands per hour in lost output and idle labor.
Inconsistent Throughput: Fluctuations in feed material hardness or size cause choke points, preventing the plant from consistently achieving its rated 250300 tph capacity.
High Operational Costs: Excessive energy consumption from inefficient drives and frequent, costly wear part replacements directly impact your costperton metric.
Regulatory & Supply Chain Friction: Sourcing components that are not uniformly RoHS compliant can lead to procurement delays, project specification noncompliance, and potential reputational risk.

The central question is: how do you specify a crushing plant that delivers reliable, rated throughput while controlling total operational expenditure and ensuring modern environmental compliance?

2. PRODUCT OVERVIEW

This product is a complete, preengineered RoHS Compliant 250300tph Stationary Stone Crushing Plant. It is designed as a turnkey solution for highvolume production of aggregates for road base, concrete, and asphalt applications.

Operational Workflow:
1. Primary Crushing: Large feed material (≤750mm) is reduced by a robust jaw crusher or primary impactor.
2. Secondary & Tertiary Crushing: Material is conveyed to cone crushers and/or secondary impactors for further size reduction and shaping.
3. Screening & Classification: Vibrating screens separate material into specified product sizes; oversize is recirculated.
4. Material Handling: A network of RoHScompliant conveyors with energyefficient drives transfers material between stages.
5. Dust Suppression: Integrated spray systems control particulate emissions at transfer points.

Application Scope: Ideal for granite, limestone, basalt, and river gravel processing in quarrying, mining, and largescale construction projects requiring consistent, highquality spec aggregates.

Limitations: This plant configuration is designed for stationary or semistationary installation. For projects requiring frequent relocation, a mobile or skidmounted solution should be considered.

3. CORE FEATURES

RoHSCompliant Component Ecosystem | Technical Basis: EU Directive 2011/65/EU | Operational Benefit: Guaranteed supply chain of hazardous substancefree electrical components, wiring, and PLC systems | ROI Impact: Eliminates procurement delays for regulated markets and futureproofs your asset against tightening global environmental standards.

Intelligent LoadSensing Hydraulic System | Technical Basis: Variable displacement pumps paired with pressurecompensated valves | Operational Benefit: Hydraulic power on demand for crusher adjustment and clearing functions reduces parasitic energy loss | ROI Impact: Field data shows up to an 18% reduction in hydraulic system energy consumption compared to fixedflow systems.

Unified PLC Control & Monitoring Platform | Technical Basis: Centralized Siemens/AllenBradley controller with HMI interface | Operational Benefit: Your operators can monitor motor loads, bearing temperatures, and production totals from a single station for proactive management | ROI Impact: Reduces fault diagnosis time by an estimated 30% and enables datadriven maintenance scheduling.

Modular Crusher Cavity & Liner Designs | Technical Basis: Interchangeable liner profiles and mantle/bowl designs for jaw and cone crushers | Operational Benefit: Enables quick reconfiguration of the crushing circuit to adapt to changes in feed material or final product specification | ROI Impact: Extends wear part life cycle by optimizing crush profiles; increases plant utilization for varied contracts.

HeavyDuty Vibrating Screen with Polyurethane Media | Technical Basis: HighGforce exciters coupled with abrasionresistant PU screen panels | Operational Benefit: Provides consistent screening efficiency with reduced blinding and lower noise generation | ROI Impact: Longer panel life reduces changeout frequency; improved accuracy minimizes recrush of onspec material.

Centralized Greasing & Lube System | Technical Basis: Automated singleline progressive system for all major crusher bearings | Operational Benefit: Ensures correct lubrication intervals without manual intervention at multiple hardtoaccess points | Operational Benefit: Mitigates bearing failure risk; documented to extend bearing service life by approximately 25%.

Structural DynamicsOptimized Support Fabrication | Technical Basis: FEA (Finite Element Analysis) designed supports and platforms to mitigate resonant vibration | Operational Benefit: Reduces structural fatigue stress on conveyors, screens, and chute work during fullload operation| ROI Impact Lowers longterm structural maintenance costs; minimizes vibrationinduced fastener failures.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | This RoHS Compliant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Energy Efficiency (kWh/ton) | ~0.85 1.0 kWh/tonne (estimated) VFDs optional| ≤0.75 kWh/tonne VFDs standard on all major drives| Up to 15% reduction |
| Wear Part Cost Index (Relative) Baseline = 100| Index of 100 (Manganese steel standard) Index of ~8590 (Hybrid/alloy options)| Index of ~80 Optimized cavity design + optional ceramic composites| Up to 20% reduction potential |
| Mean Time Between Failure (MTBF) Electrical Components| Varies widely based on component sourcing.| Increased MTBF Guaranteed RoHS compliance ensures highergrade industrial components| Documented ~40% improvement in component reliability |
| Throughput Consistency (% of time at rated capacity)| ~8085% due to feed variation & blockages.| ~9092% Intelligent load management & cavity optimization| ~7% increase in operational availability |

5. TECHNICAL SPECIFICATIONS

Designed Capacity: 250 300 tonnes per hour (tph), depending on feed material hardness (<200 Mpa recommended) and final product size.
Primary Crusher Options: Jaw Crusher (PE900×1200) or HeavyDuty Primary Impact Crusher.
Secondary/Tertiary Stage: Combination of MultiCylinder Hydraulic Cone Crushers (e.g., HPC315) and/or Secondary Impact Crushers.
Screening Stage: Tripledeck heavyduty vibrating screen (3YK3072).
Power Requirement: Total installed power approximately 800 950 kW. Requires stable threephase industrial supply.
Key Material Specifications: All electrical components (wiring, PLCs relays sensors switches etc.) comply with EU RoHS Directive Restriction of Hazardous Substances). Major steel structures utilize S355JR grade steel; wear liners use highmanganese steel or optional ceramic composites.
Approximate Footprint: ~75m (L) x 45m (W), subject to final layout configuration.
Environmental Operating Range: Designed for 10°C to +45°C ambient temperature Dust suppression system maintains operation within local particulate emission standards

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project Challenge A quarry needed to expand output but faced strict new environmental regulations requiring RoHScompliant equipment for the entire site upgrade Their existing plant suffered from low electrical reliability Solution Installation of this RoHS compliant tph stone crushing plant as the new primary production line Results The project met the tender's environmental specification exactly achieving consistent tph output Postinstallation analysis showed a % reduction in electrical component failures compared to the older line

LargeScale Infrastructure Contractor Challenge A contractor securing multiple projects with varying aggregate specifications required flexible highvolume production without constant reinvestment Frequent changeovers were causing significant downtime Solution Implementation of the modular crushing plant featuring quickly reconfigurable crusher cavities liner sets Results The crew can now reconfigure the circuit from producing road base to concrete aggregate in under hours Plant utilization increased by enabling fulfillment of diverse contracts

Aggregate Producer Focused on TCO Total Cost Ownership Challenge Rising energy costs unpredictable wear part expenses were making costperton projections unreliable Management needed predictable operational expenditure Solution Adoption of the complete solution featuring loadsensing hydraulics standard VFDs optimized wear parts Results Achieved a documented kWh tonne saving stabilized monthly consumables spend leading to a predictable costperton model that improved bidding accuracy

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around core configuration choices:

Tier Basic Configuration Includes primary jaw crusher secondary cone crusher tripledeck screen basic conveyors central control panel
Tier Enhanced Configuration Adds tertiary crushing stage VFDs on all major drives upgraded polyurethane screen media automated greasing system
Tier Turnkey Premium Includes full dust suppression enclosure advanced rockbreaker at feed hopper comprehensive spare parts package extended commissioning support

Optional Features Onboard power generation package advanced particle size monitoring system remote telematics connectivity extra set of wear parts
Service Packages Available Annual inspection maintenance contracts operator training programs guaranteed critical parts availability within hours
Financing Options Flexible leasing structures operating lease finance lease available through partnered institutions can be tailored to match project cash flow timelines

8 FAQ

What does 'RoHS Compliant' mean specifically for this crushing plant It means all electrical electronic components within the plant from motors wiring control cabinets PLCs sensors lighting are manufactured without restricted hazardous substances like lead mercury cadmium This ensures compliance with EU other international markets simplifies disposal recycling

How does this plant handle variations in feed material hardness The combination multi cylinder hydraulic cone crushers allows realtime adjustment CSS Closed Side Setting via the PLC interface This along selectable cavity profiles lets operators tune performance maintain product spec without stopping

What is typical installation commissioning timeline For greenfield site typical timeline weeks from delivery completion civil works This includes days onsite commissioning operator training by factory engineers Timeline varies based site preparedness

Are spare parts readily available given specialized components Yes Core wear parts mantles concaves jaw plates are standardized common models Nonwear electrical components are industrystandard RoHS compliant items ensuring global availability through our network local distributors

Can existing equipment be integrated into this new plant system Yes The control system designed accommodate integration legacy equipment conveyors screens provided their specifications compatible Engineering review required ensure seamless interoperability