1. PAINPOINT DRIVEN OPENING

Are you managing a stone quarry operation where profit margins are consistently pressured by equipment performance? The challenges of primary crushing are often the bottleneck. Consider these common operational hurdles:
Excessive Downtime for Maintenance: Frequent liner changes, unexpected bearing failures, and wear part replacement halt your entire production line, costing thousands per hour in lost revenue.
Inconsistent Feed Size & Throughput: Bridging, segregation, and irregular feed from the quarry face lead to poor crusher cavity fill, reducing capacity and increasing wear unevenly.
High Operational Costs: Soaring energy consumption per ton of processed material, coupled with the high and frequent cost of wear parts like mantles, concaves, and jaw plates, directly erode profitability.
Product Quality Inconsistency: Inability to reliably control topsize output or an excessive proportion of flaky material can impact downstream processes and final product marketability.
Safety & Accessibility Concerns: Routine inspections and maintenance tasks that are timeconsuming or require personnel to work in hazardous proximity to the equipment.

Is your primary crushing station a source of reliability or a recurring cost center? The right contract manufacturer for your stone quarry crushing plant addresses these issues at the design phase, focusing on total cost of ownership rather than just initial purchase price.

2. PRODUCT OVERVIEW

This content outlines the critical considerations for a stationary primary jaw crusher station within a complete stone quarry crushing plant. Designed as the first mechanical reduction stage, this system is engineered for high availability and low costperton in hard rock applications like granite, basalt, and limestone.

Operational Workflow:
1. Feed Intake: Dump trucks or wheel loaders discharge runofquarry (ROQ) material into a rugged vibrating grizzly feeder (VGF).
2. PreScreening & Fines Removal: The VGF scalps out natural fines and subcrushsize material via its grizzly bars, bypassing the crusher to increase efficiency and reduce wear.
3. Primary Reduction: Oversize material is conveyed into the jaw crusher cavity, where compressive force between a fixed and a moving jaw plate fractures the rock.
4. Discharge & Conveyance: Crushed material is discharged onto a main product conveyor for transport to secondary crushing or stockpiling.

Application Scope & Limitations:
Scope: Ideal for hightonnage, abrasive hard rock quarries requiring a robust primary breaker. Optimal for material with compressive strength up to 400 MPa.
Limitations: Not suitable for sticky, clayrich materials without preprocessing. A gyratory crusher may offer superior throughput for capacities exceeding 1,500 tph in certain configurations.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder (VGF) | Technical Basis: Highstrength steel plate construction with boltin AR liners | Operational Benefit: Regulates feed rate to the crusher, eliminates bridging, removes fines to prevent crusher packing | ROI Impact: Increases effective crusher capacity by up to 15% and reduces unnecessary wear on crusher components

WedgeBased Jaw Plate Adjustment System | Technical Basis: Mechanically locked wedges replace traditional shim plates | Operational Benefit: Enables safe, fast CSS adjustment and jaw plate changes from the crusher’s nondrive side in under two hours | ROI Impact: Reduces downtime for routine adjustments by approximately 60%, maximizing productive operating hours

Optimized Crushing Chamber Geometry | Technical Basis: Computermodeled kinematics and nip angle design | Operational Benefit: Promotes deepbed crushing throughout the chamber for consistent particleonparticle breakage | ROI Impact: Produces a more cubical product shape (improving secondary crush efficiency) and extends jaw plate service life by distributing wear more evenly

Integrated Motor Base & Belt Guard | Technical Basis: Unified steel fabrication housing crusher motor(s) and drive guards | Operational Benefit: Eliminates complex field alignment during installation; provides safe, integral guarding compliant with site safety standards | ROI Impact: Reduces installation time and cost by up to 30%, ensuring faster commissioning

Centralized Greasing Points & Condition Monitoring Ports | Technical Basis: Lube lines routed to accessible groundlevel stations with ports for vibration/temperature sensors | Operational Benefit: Enables daily lubrication and health checks without operators needing to access elevated platforms near moving parts | ROI Impact: Enhances preventative maintenance adherence, improving bearing life and preventing catastrophic failures

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Stone Quarry Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner ChangeOut Time | 68 hours (Jaw Plates) | < 2 hours (Jaw Plates) | ~70% faster |
| Energy Efficiency| 0.85 1.1 kWh/ton processed| Target: 10% improvement |
| Crusher Availability| ~9294% (scheduled & unscheduled)| Design Target: >96%| ~34% increase |
| Wear Part Utilization| ~6070% of theoretical weight used before changeout| Design enables use of >85% of liner mass| ~25% better utilization |

5. TECHNICAL SPECIFICATIONS

Model Reference: STQPrimary1442HD
Crusher Type: HeavyDuty Single Toggle Jaw Crusher
Feed Opening: 1400mm x 1100mm (55" x 42")
Maximum Feed Size: 1000mm (40") edge length
Closed Side Setting (CSS) Range: 150mm 300mm (6" 12")
Capacity Range: 450 850 metric tph (dependent on feed gradation & CSS)
Drive Power Requirement: 200 kW (275 HP), electric motor with softstart compatibility
Total Plant Power Demand (Feeder/Crusher/Conveyors): Approx. 350 kW
Key Material Specifications: Main frame fabricated steel plate; Jaw plates Manganese steel alloy; Shaft forged alloy steel; Bearings spherical roller type.
Approximate Footprint (L x W): 18m x 8m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dustsealed bearings; weather protection covers standard.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: An existing granite quarry needed to expand production but was constrained by an aging primary plant causing over 40 hours of unplanned downtime monthly due to reliability issues.
Solution: Contract design and supply of a complete new primary stone quarry crushing plant station built around a heavyduty jaw crusher with enhanced accessibility features.
Results: Postinstallation data showed plant availability increased from 88% to 96%. Unplanned downtime was reduced by over 90%, enabling the site to meet its expanded production target within six months.

Basalt Aggregate Producer Seeking Cost Control

Challenge: A producer faced volatile profitability due to uncontrollably high energy costs per ton and rapid wear part consumption in their primary stage.
Solution: Implementation of an optimized plant design featuring chamber geometry focused on energyefficient breakage and a feeder system that removed more fines prior to crushing.
Results: Field data tracked over one year showed a reduction in specific energy consumption from 0.98 kWh/ton to 0.82 kWh/ton—a direct utility cost saving—and extended average jaw plate life by approximately 22%.

7. COMMERCIAL CONSIDERATIONS

Our approach as your contract manufacturer is based on transparent value engineering:

Pricing Tiers
1. Standard Plant Package includes core equipment as specified above with basic walkways/platforms.
2.Optimized Plant Package includes additional features such as dust suppression system integration advanced condition monitoring sensor packages automated grease systems (+1015%)
3.Turnkey Project Package includes full civil design support installation supervision commissioning services (+varies)

Optional Features include metal detection systems tramp iron relief automation hydraulic setting adjustment vs manual modular skid designs for faster relocation

Service Packages:
• Commissioning Support Onsite training operational readiness review
• Planned Maintenance Contracts Guaranteed parts supply scheduled inspections fixed annual cost models
• Performance Audits Annual review of throughput wear rates efficiency recommendations

Financing Options available through our partners include capital lease operating lease longterm rentaltoown structures tailored typically over 3 7 10year terms

8.FAQ

Q What if my current secondary crushers are not from your company? Is compatibility an issue?
A No Our stone quarry crushing plant is designed as an independent modular station Output specifications including product size distribution are engineered based on your input requirements ensuring seamless interface with any downstream equipment via proper transfer conveyors

Q How does this solution address my high energy costs?
A Energy efficiency is engineered into multiple components including optimized feedercrusher interaction efficient drive motor selection correctly sized gearboxes The overall system design aims minimize bottlenecks that cause motors run underloaded which inefficient Field data shows our optimized plants typically achieve measurable reductions specific energy consumption kWh per ton processed

Q What guarantees do you provide on performance metrics like throughput?
A We provide process performance guarantees based agreedupon feed material characteristics These are detailed commercial terms within contract specifying test methods duration We guarantee mechanical performance structural integrity workmanship standard industryleading warranties major components

Q Can you accommodate limited space on my existing site?
A Yes As contract manufacturer we specialize designing plants fit constrained layouts offering modular configurations vertical arrangements reduce footprint compared traditional horizontal flow designs Detailed layout studies conducted during proposal phase ensure feasibility before commitment made

Q What typical lead time expected from contract signing delivery?
A For standard configured stone quarry crushing plant lead times typically range 6 9 months depending complexity current manufacturing schedule Expedited options may available additional cost Longlead items like castings forgings identified early process