1. PAINPOINT DRIVEN OPENING

Are you managing a highvolume aggregate operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, the challenges of a 250300tph stone crushing plant are often quantifiable: unpredictable downtime from component failures, escalating maintenance labor costs, inconsistent final product gradation leading to rejected loads, and the high capital risk of integrating equipment from multiple vendors. These issues directly impact your bottom line. How do you ensure consistent throughput to meet tight project schedules? Can you reduce unplanned maintenance intervals without sacrificing capacity? Is your current setup optimized for the lowest cost per ton over a 10year lifecycle? The solution lies in a fully integrated, whitelabel crushing plant engineered for reliability and efficiency.

2. PRODUCT OVERVIEW

This product is a complete, stationary White Label 250300tph Stone Crushing Plant, designed as a turnkey solution for highcapacity production of aggregates for road base, concrete asphalt, and railway ballast. The plant is configured for primary, secondary, and tertiary crushing stages to produce precisely graded cubical aggregates.

Operational Workflow:
1. Primary Jaw Crushing: Large feed material (up to 750mm) is reduced to <200mm by a robust jaw crusher.
2. Secondary Cone Crushing: Material is conveyed to a cone crusher for further reduction, shaping the aggregate.
3. Sizing & Separation: Crushed material is screened via multideck vibrating screens; onspec product is diverted to stockpiles.
4. Tertiary Shaping (Optional): Oversize material is recirculated through an impact crusher (VSI) for fine shaping and sand production.
5. Integrated Conveying: A network of heavyduty conveyors with centralized control manages material flow between all stages.

Application Scope: Ideal for large quarry operations, major infrastructure projects requiring onsite aggregate production, and dedicated aggregate supply yards serving metropolitan regions.

Limitations: This configuration requires stable foundational ground for installation, threephase highvoltage power supply, and is designed for mediumtohard abrasion index stones (e.g., granite, basalt). For highly mobile or frequent relocation needs, a modular skidmounted system may be more appropriate.

3. CORE FEATURES

Unified Control System | Technical Basis: Centralized PLC with SCADA interface | Operational Benefit: Singlepoint monitoring and control of the entire crushing circuit enables rapid adjustment of feed rates and crusher settings to maintain target gradation. | ROI Impact: Reduces operator headcount requirements by up to 30% and minimizes offspec production waste.
HeavyDuty Vibrating Feeder with Grizzly Section | Technical Basis: Reinforced steel plate feeder with adjustable grizzly bars | Operational Benefit: Ensures consistent, regulated feed to the primary crusher while scalping out natural fines, preventing crusher choke and reducing wear on primary crushing chamber. | ROI Impact: Increases primary crusher efficiency by an estimated 1520%, extending liner life.
Hydraulic Adjustment & Clearing on Crushers | Technical Basis: Integrated hydraulic systems on jaw and cone crushers | Operational Benefit: Allows operators to adjust crusher settings or clear blockages in minutes without manual disassembly, even under load. | ROI Impact: Cuts downtime related to chamber clearing and CSS adjustment by over 80% compared to manual systems.
Dust Suppression & Containment System | Technical Basis: Atomized spray nozzles at transfer points with encapsulation skirts | Operational Benefit: Significantly reduces airborne particulate matter, ensuring compliance with environmental regulations and improving site working conditions. | ROI Impact: Mitigates risk of regulatory fines and reduces healthrelated absenteeism among personnel.
HighCapacity Conveyor Design | Technical Basis: Oversized idlers, impact beds at loading points, and variable frequency drives (VFDs) | Operational Benefit: Handles peak loads without spillage or belt damage; VFDs allow soft starts and optimized power consumption matched to actual load. | ROI Impact: Extends conveyor belt life by approximately 40% and reduces energy consumption of the conveying system.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Setup) | White Label 250300tph Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability | ~7580% (due to component mismatch & downtime) | 92%+ (engineered integration & reliability focus) | 1520% Improvement |
| Cost per Ton (Maintenance)| Based on disparate part sourcing & labor hours| Consolidated service contracts & common parts inventory| Up to 25% Reduction |
| Product Gradation Consistency| Varies due to independent process stages| Tight control via integrated process logic & feedback| Variability Reduced by ~30% |
| Installation & Commissioning Time| 812 weeks (multivendor coordination)| 56 weeks (singlesource responsibility)| Time Savings of ~40% |
| Energy Consumption (kWh/ton)| Baseline from nonoptimized systems| Optimized motor selections & conveyor VFDs| Estimated 1015% Savings |

5. TECHNICAL SPECIFICATIONS

Designed Throughput Capacity: 250 300 metric tons per hour (tph) of crushed stone aggregate, dependent on feed material hardness (<180 MPa recommended) and required final product size.
Power Requirements: Total installed power approximately 550 650 kW. Requires primary supply voltage of 10kV or transformable medium voltage supply.
Key Material Specifications:
Primary Crusher Jaw Plates / Cone Liners: High manganese steel (Mn18Cr2).
Screen Decks: Harp wire or polyurethane modular panels.
Conveyor Belting: EP630/4 minimum rating with top cover ≥10mm.
Structural Steel Frame: S355JR grade painted with industrial epoxy system.
Approximate Footprint: ~75m L x 45m W x 15m H (excluding stockpiles). Foundation design loads provided upon geotechnical survey.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with optional heating/cooling packages for extreme climates.

6. APPLICATION SCENARIOS

Large Limestone Quarry Expansion

Challenge A quarry supplying regional concrete plants needed to increase output but was constrained by an aging twostage plant causing excessive fines production (>25%) in the target 57 stone specification.

Solution Implementation of this whitelabel threestage plant featuring a cone crusher in closed circuit with sizing screens followed by a tertiary impactor for reshaping oversize.

Results Final product yield in the target 57 specification increased from ~65% to over 88%, while overall plant throughput stabilized at a sustained rate of >280 tph.

Major Highway Construction Project

Challenge A contractor on a remote highway corridor faced prohibitive costs of transporting aggregates over long distances and needed reliable onsite production meeting strict DOT gradation controls.

Solution Deployment of this preengineered whitelabel crushing plant configured specifically for highabrasion basalt feed from the project's borrow pit.

Results The project achieved selfsufficiency in aggregate supply within eight weeks of equipment delivery; consistent gradation compliance eliminated any load rejections at the asphalt mixing plants along the corridor.

Aggregate Recycling Operation

Challenge An urban recycling center processing demolished concrete sought highervalue products but struggled with contamination removal in their singlestage setup.

Solution Integration of this plant's heavyduty feeder/grizzly section combined with an electromagnetic separator over the primary conveyor before secondary crushing stages.

Results Contaminant removal efficiency improved from ~70% to >95%, allowing production of clean RCA meeting DOT Class II specifications at volumes exceeding >260 tph processed C&D waste

COMMERCIAL CONSIDERATIONS

The capital investment for a whitelabel stone crushing plant solution varies based on configuration depth:

Pricing Tiers:
Tier I Base Plant Includes primary jaw secondary cone screening towers main conveyors central control cabin electrical package $1M $1M
Tier II Enhanced Plant Adds tertiary shaping VSI advanced dust suppression system automated lubrication system $1M $1M
Tier III Turnkey Package Includes full civil engineering drawings erection supervision commissioning training extended warranty $1M+

Optional Features:
Onboard power generation package automated metal detection magnetic separation systems remote telematics monitoring additional stockpile conveyors

Service Packages:
Standard hours onsite commissioning operator training
Premium Annual preventative maintenance contract guaranteed parts availability within hours priority technical support
Platinum Full operational maintenance contract fixed cost per operating hour covering all parts labor consumables excluding wear liners

Financing Options:
Equipment leasing structures operating leases project financing through partner institutions milestonebased progress payments

FAQ

What are the lead times typically involved?
From order confirmation delivery ranges between weeks depending on final configuration complexity Factory acceptance testing FAT can be arranged prior shipment

How does this integrate with our existing screening or conveying equipment?
Our engineering team can conduct an audit Your existing equipment can often be incorporated into new plant design provided it meets capacity structural requirements avoiding unnecessary capital expenditure

What level operator training is provided?
Comprehensive training covers daily startup/shutdown procedures routine maintenance troubleshooting basic adjustments Training conducted both during commissioning ongoing basis as needed

Are wear parts readily available given it's white label?
Yes All critical wear parts jaw plates cone mantles screen media are manufactured standard dimensions held regional distribution centers ensuring availability comparable major OEM brands

What guarantees are provided on throughput capacity?
Plant performance guarantee provided based mutually agreed upon feed material characteristics sample testing Final performance validation conducted during commissioning using calibrated weighing equipment