1. PAINPOINT DRIVEN OPENING

Managing the logistics of a stationary stone crusher plant relocation or a new greenfield project presents significant, costly hurdles. Commercial buyers and project managers face consistent challenges: exorbitant transportation costs for preassembled modules, prolonged onsite assembly times that delay revenue generation, and complex civil work requirements for fixed foundations that escalate project budgets. Are you contending with unpredictable shipping timelines, damage to critical components in transit, or the high labor costs of extended field commissioning? These operational bottlenecks directly impact your project's bottom line and timeline. The solution lies not just in the crusher itself, but in a fundamentally optimized approach to its delivery and deployment.

2. PRODUCT OVERVIEW

This product line focuses on modular and semimobile stone crusher plants engineered specifically for simplified shipping and rapid deployment. Unlike traditional stationary plants requiring piecebypiece shipment and complex onsite construction, these units are designed as preengineered modules.

Operational Workflow:
1. Factory Assembly & Testing: Core crushing and screening circuits are assembled, wired, and fully tested under load in a controlled factory environment.
2. Modular Shipping: Certified modules are shipped via standard flatbed trailers or containers, minimizing dimensional issues and reducing freight costs.
3. Site Preparation: Requires only simple concrete foundations or compacted gravel pads, significantly reducing civil engineering scope.
4. Rapid Connection: Modules are positioned, with interconnecting conveyors, walkways, and electrical connections designed for bolttogether efficiency.
5. Commissioning: Due to pretesting, site commissioning focuses on system integration and can be completed in days rather than weeks.

Application Scope & Limitations: Ideal for greenfield sites, temporary quarry developments, contract crushing projects requiring relocation, and operations where capital expenditure on permanent civil works must be minimized. These plants may have a higher initial unit cost compared to equivalent capacity fixed plant blueprints but offer lower total installed cost. Maximum capacity per single modular unit is typically below that of the largest custombuilt stationary plants.

3. CORE FEATURES

PreAssembled Chassis Modules | Technical Basis: Unitized structural frame design | Operational Benefit: Eliminates weeks of onsite steel fabrication and alignment; modules arrive ready to liftandplace | ROI Impact: Reduces installation labor costs by up to 60% and accelerates timetoproduction
Containerized Electrical Systems | Technical Basis: IECstandard enclosure protection (IP65) | Operational Benefit: Protects sensitive PLCs, drives, and switchgear from moisture and dust during shipping and operation; simplifies cable interconnection | ROI Impact: Minimizes electrical downtime risks; reduces commissioning time by approximately 40%
Hydraulic Folding Conveyors | Technical Basis: Engineered hinge points with integrated hydraulic cylinders | Operational Benefit: Conveyors ship within standard width limits and unfold to operational position without disassembly | ROI Impact: Cuts conveyor setup time from days to hours; eliminates need for mobile cranes during routine reconfiguration
Integrated Lifting & Transport Points | Technical Basis: CAD/FEAoptimized lift lug design integrated into main structure | Operational Benefit: Provides certified, clearly marked points for safe rigging during both initial placement and future relocation | ROI Impact: Enhances safety during moves; prevents costly structural damage from improper lifting
Standardized InterModule Connections | Technical Basis: Flanged mechanical chutes & quickdisconnect electrical/pneumatic couplings | Operational Benefit: Ensures leakfree material transfer and reliable utility connections between modules with minimal field labor | ROI Impact: Drives predictable installation schedules; facilitates easier future plant expansion or reconfiguration

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Traditional Fixed Plant) | Modular Crusher Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| OnSite Installation Time | 812 weeks (foundation cure + assembly) | 24 weeks (pad preparation + module connection) | Up to 70% faster |
| Shipping Cost Factor (per ton of equipment) High due to oversized/overweight components) Optimized for standard road transport dimensions Up to 35% lower |
| PreCommissioning Reliability Components tested individually System tested as integrated unit under load Field startup issues reduced by ~80% |
| Relocation Feasibility Essentially permanent; relocation is a demolition/rebuild process Designed for systematic disassembly/reassembly Enables strategic asset redeployment |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 150 600 tonnes per hour (TPH), depending on model configuration (Jaw/Cone/Impactor).
Power Requirements: Plantwide requirement from 300 kVA to 1 MVA; supplied via modular power distribution panel.
Material Specifications: Primary structure fabricated from S355JR steel; wear liners in AR400 steel; chute work in Hardox® abrasionresistant steel.
Physical Dimensions (Per Module): Designed for legal road transport. Max shipping dimensions typically L15m x W3m x H4.5m per trailer.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression system included as standard.

6. APPLICATION SCENARIOS

Contract Crushing Company Expansion

| Challenge Required rapid deployment into a new 18month quarry contract with minimal site preparation investment.| Solution Implementation of a semimodular jawandscreen plant with hydraulic folding conveyors.| Results Plant was operational within 17 days of equipment arrival on site; achieved target production within first week; enabled profitable execution of shortterm contract.

Remote Aggregate Supply Project

| Challenge Supplying ballast material for a rail project in a location with limited local labor skills and no existing heavy industrial infrastructure.| Solution A fully containerized crushing circuit shipped via sea container to nearest port.| Results Modules served as their own weatherproof enclosures; plugandplay connections reduced required specialist commissioning time by 50%; project met critical path schedule.

Quarry Modernization & Flow Sheet Change

| Challenge Need to replace an aging primary crushing station without halting downstream processing for an extended period.| Solution A preassembled primary crushing module was commissioned adjacent to the existing setup.| Results The new module was tied into the existing conveyor system over a scheduled 72hour maintenance shutdown, minimizing production loss during transition.

7. COMMERCIAL CONSIDERATIONS

Our modular stone crusher plant solutions are offered in three primary tiers:
1. Standard Configuration: Predesigned layouts covering the most common applications (e.g., limestone granite). Includes core crushing module(s), basic onboard electricals.
2. ApplicationOptimized Tier: Customized with specific wear packages screen media types or dust control upgrades tailored to your feed material specifications.
3. Fully Autonomous Ready Tier: Includes infrastructure provisions sensor mounting points control system architecture for future automation integration.

Optional features include advanced dust suppression systems hybrid diesel/electric drive options sound attenuation enclosures extended walkway packages.

We offer comprehensive service packages including supervised installation commissioning multiyear preventive maintenance agreements remote monitoring support Financing options including leasing capital equipment loans are available through our financial partners subject to credit approval.

FAQ

1.Q What is the lead time difference between this modular approach versus building a traditional stationary plant?
A Industry data indicates modular plants can be delivered siteready up to six months faster due concurrent factory fabrication while site preparation occurs

2.Q How does the longterm maintenance cost compare?
A Maintenance costs are comparable however accessibility designed into modular units often reduces service time Field data shows bearing inspection tasks can be completed up faster due improved access layouts

3.Q Can these plants be expanded after initial purchase?
A Yes The standardized connection design allows additional screening or secondary tertiary crushing modules be integrated later providing flexibility your operation grows

4.Q Are there financing advantages this model?
A Potentially yes Because asset is relocatable retains higher residual value some financial institutions offer favorable lease terms recognizing redeployment potential

5.Q What level site preparation required?
A Typically requires compacted subbase simple concrete foundation pads each major module point Detailed geotechnical report foundation drawings provided part engineering package

6.Q How handled aftersales service technical support?
A Each plant supported identical OEM parts service network traditional models Additionally digital documentation wiring diagrams specific your serialnumbered unit ensures accurate support

7.Q Is performance guaranteed same fixed plant equivalent model?
A Yes Factory load testing ensures each module meets published performance specifications throughput product gradation before shipment Performance guarantees based same criteria