1. PAINPOINT DRIVEN OPENING

Are unpredictable equipment failures and inconsistent product gradation eroding your plant's profitability? Inconsistent feed material, abrasive wear, and unplanned maintenance are not just operational nuisances—they directly impact your bottom line through excessive downtime, high replacement part costs, and missed production targets. Consider these common challenges:
Variable Feedstock: Fluctuations in material hardness, moisture, or size lead to chokeups, reduced throughput, and offspec product.
Unscheduled Downtime: Component failures during critical production windows can cost thousands per hour in lost revenue and idle labor.
High Wear Costs: The constant abrasion from crushing and screening operations results in frequent, costly liner and screen media replacements.
Energy Inefficiency: Older or poorly calibrated equipment draws excessive power without delivering proportional output, inflating operational expenses.
Data Gaps: Operating without clear performance metrics makes it difficult to optimize processes or justify capital expenditures for upgrades.

How can you achieve reliable throughput while controlling operational costs? The answer lies in rigorous, datadriven evaluation before procurement. This is where professional Sustainable Crushing And Screening Equipment Testing transitions from an optional check to a critical business investment.

2. PRODUCT OVERVIEW

Sustainable Crushing And Screening Equipment Testing is a comprehensive, analytical service designed to validate the performance, durability, and economic viability of crushing and screening machinery under controlled, simulated realworld conditions. This process mitigates procurement risk by providing empirical data before a fullscale purchase.

The core workflow involves:
1. Material Characterization: Detailed analysis of your specific feedstock (e.g., compressive strength, abrasiveness, moisture content).
2. BenchScale & PilotScale Testing: Operating candidate equipment with your material to measure throughput, power draw, wear rates, and product shape/size distribution.
3. Data Acquisition & Monitoring: Continuous logging of operational parameters (loads, pressures, temperatures) to identify stress points.
4. Wear Life Analysis: Posttest inspection and measurement of critical wear components to project liner life and operating costs.
5. Performance & Economic Reporting: Synthesis of all data into a clear report detailing expected capacity, total cost of ownership (TCO), and ROI projections.

Application Scope: This service is applicable to primary gyratory crushers, cone crushers, jaw crushers impact crushers vibrating screens feeders for mining aggregates cement production mineral processing
Limitations: Testing provides highly accurate projections but cannot account for every variable of fullscale continuous operation over years Ultimate equipment life is influenced by sitespecific maintenance practices

3. CORE FEATURES

Proprietary WearTracking Methodology | Technical Basis: Laserscanning of liners/screens pre posttest to calculate precise volume loss | Operational Benefit: Delivers accurate predictive wear life models for your specific material enabling reliable spare parts budgeting | ROI Impact: Reduces risk of unexpected consumable costs by up to 40% through accurate forecasting

RealTime Load & Pressure Monitoring | Technical Basis: Instrumentation of hydraulic systems drive components bearings to record dynamic operational stresses | Operational Benefit: Identifies potential overload conditions and ensures selected equipment operates within its optimal efficiency range | ROI Impact: Prevents premature failures; field data shows a typical 1525% extension in major component life through optimized selection

Granular Product Analysis | Technical Basis: Automated sieve analysis particle shape imaging (e.g flakiness index cubicity) of output material | Operational Benefit: Confirms the equipment can meet your precise product specifications for downstream processes or market requirements | ROI Impact: Minimizes product rejection/recrush cycles improving overall plant yield

Energy Consumption Profiling | Technical Basis: Integrated power meters measuring kWh/tonne crushed or screened across various load settings | Operational Benefit: Provides definitive data on the most energyefficient operating parameters for your application | ROI Impact: Enables selection of the most efficient machine reducing lifetime energy costs which can constitute up to 40% of TCO

System Integration Simulation | Technical Basis: Testing feedercrusherscreen interactions in a closedloop pilot circuit where applicable | Operational Benefit: Reveals bottlenecks compatibility issues between units before they are installed in your plant layout | ROI Impact: Avoids costly reengineering postinstallation ensuring designed throughput is achievable

Abrasion Index Correlation | Technical Basis: Conducting standardized abrasion tests (e.g Bond Ai Cerchar) on your feedstock correlating results with measured wear rates during equipment test| Operational Benefit: Creates a quantifiable database linking your material properties directly to equipment wear performance| ROI Impact Allows for intelligent crosscomparison of different machine technologies based on your most punishing cost driver material abrasiveness

4 COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Approach | Sustainable Crushing And Screening Equipment Testing Solution Advantage (% improvement) |
| : | 😐 😐 : |
| Wear Life Prediction Accuracy | Ruleofthumb based on generic material class Datadriven projection based on actual measured wear from your processed feedstock 2550% more accurate forecasts |
| TesttoReality Throughput Correlation Vendorrated capacity under ideal conditions Capacity validated with your variable feed including fines moisture Achieves >95% correlation in field validation studies |
| Energy Efficiency Validation Manufacturer stated power draw Measured kWh/tonne under load profile simulating your shift patterns Identifies potential savings variances up to ±20% |
| Total Cost of Ownership (TCO) Model Focus on initial purchase price Comprehensive model including projected energy wear parts maintenance labor over a 5year period Enables holistic comparison reducing TCO by 1030% |

5 TECHNICAL SPECIFICATIONS

Testing Capacity Range: Can process from 500kg benchscale batches up to pilotscale continuous circuits handling 1050 tonnes per hour depending on machine type
Feedstock Size Acceptance: Up to 80% of target machine s maximum feed size typically up to 200mm for secondary/tertiary units
Power Requirements Test Facility Fully equipped with appropriate industrial power supplies (400V690V 50/60Hz) instrumentation
Material Specifications Tested Equipment constructed from industrystandard materials AR steel manganese steel polyurethane etc
Physical Dimensions Test Bays designed accommodate equipment footprints up to approx 10m x 5m with adequate overhead clearance
Environmental Operating Range Conducted in a controlled indoor facility eliminating weather variables temperature maintained between +5°C +35°C

6 APPLICATION SCENARIOS

Aggregate Producer Expanding into Harder Geologies Challenge A regional aggregate producer planned expansion into new hard abrasive granite deposits but lacked experience with required crusher technology Risked selecting underperforming or excessively highwear equipment Solution A comprehensive Sustainable Crushing And Screening Equipment Testing program comparing two shortlisted cone crusher technologies using actual granite samples Results Test data revealed one candidate had a 38 lower kWh/tonne energy consumption and projected liner life was 22 longer The selected unit met spec achieving plant capacity with TCO savings exceeding $180000 annually versus the alternative

Iron Ore Processor Optimizing Circuit Efficiency Challenge An iron ore processing plant experienced bottlenecks inconsistent final product size from aging secondary crushers leading to downstream mill inefficiencies Management needed justification for capital replacement Solution Targeted testing focused on modern highpressure grinding roll HPGR technology versus advanced cone crushers using current plant runofmine ore Results The testing quantified a 28 improvement in energy efficiency per tonne with the HPGR option producing more consistent finer product that would increase downstream mill throughput The data secured capital approval implementation led to a projected annual increase in concentrate output

7 COMMERCIAL CONSIDERATIONS

Sustainable Crushing And Screening Equipment Testing is offered as a service typically structured around the scope complexity:

Pricing Tiers
Basic Material Characterization Wear Index Analysis Fixed fee provides essential feedstock data for initial vendor discussions
Standard SingleMachine Test Includes full performance wear energy testing on one unit with detailed report Most common selection
Comparative MultiMachine Test Sidebyside evaluation of two or three competitor machines providing direct comparative TCO analysis
Advanced ClosedLoop Circuit Simulation Pilotscale testing integrating multiple units feeders screens

Optional Features Posttest finite element analysis FEA on highstress components extended wear modeling over different liner profiles lifecycle cost software integration

Service Packages Often bundled with prepurchase advisory posttest implementation support Some providers offer test credit applied against future equipment purchase

Financing Options Testing service fees are typically operational expenditures OpEx Some providers offer leasing arrangements for the test equipment itself or projectbased financing

8 FAQ

What if my exact feedstock cannot be shipped to a test facility?
Test centers use sophisticated correlation methods If shipment isn t feasible they will work with you source the closest commercially available analog material characterize both perform correction analyses based on established indices like Bond Ai

How long does a typical test program take from start final report?
For standard singlemachine testing including logistics setup execution analysis reporting allow approximately weeks Complex multimachine comparative studies may require weeks

Can you test used or refurbished equipment I am considering purchasing?
Yes provided the machine is safe operational can be transported Many testing services include an enhanced mechanical inspection component which adds significant value when evaluating used assets identifying impending failures.

How does the cost testing compare risk making wrong multimillion dollar purchase decision?
The testing service fee typically represents < % total capital cost being evaluated It directly mitigates risk selecting underperforming inefficient machinery which can result losses far exceeding times test investment through higher operating costs lost production.

Do you provide performance guarantees based on test results?
Reputable testing agencies will provide detailed performance warranties correlation statements They guarantee accuracy measurements methodologies conducted not ultimate field performance which depends factors outside their control like site maintenance However their reports form strong basis commercial performance guarantees from equipment vendors