Subject: White Label Iron Ore Crushing Plant Bulk Order – Engineered for HighVolume, LowCost Production

1. PAINPOINT DRIVEN OPENING

Every ton of iron ore you process carries hidden costs. Are your current crushing circuits struggling with excessive liner wear from high silica content, forcing unscheduled downtime every 72 hours? Is your plant manager reporting a 1520% reduction in throughput during the wet season due to material clogging in standard cone crushers? Have you calculated the financial impact of a 4hour crusher jam—typically $12,000 to $18,000 in lost production and labor costs per incident?

For engineering contractors and commercial buyers managing bulk orders, the challenge is consistent: achieving a P80 of 812mm for downstream ball mill feed without sacrificing wear life or energy efficiency. Standard mobile plants often lack the structural integrity for 24/7 operation, while custom builds carry long lead times and high capital expenditure.

How do you secure a whitelabel solution that delivers OEMgrade metallurgy, meets your specific bulk order volume (e.g., 500,000+ tons per annum), and integrates into your existing conveyor and screening infrastructure without costly civil works?

2. PRODUCT OVERVIEW

This White Label Iron Ore Crushing Plant is a stationary or semimobile, multistage crushing system designed specifically for highabrasion, highdensity iron ore (Banded Iron Formation, Hematite, Magnetite). It operates as a closedcircuit configuration to maximize reduction ratios while minimizing recirculating load.

Operational Workflow:
1. Primary Jaw Crushing: Runofmine ore (up to 1000mm) is reduced to 200mm via a heavyduty hydraulic jaw crusher with a Vbelt drive system.
2. Scalping & PreScreening: Vibrating grizzly feeder removes fines (40mm) before the secondary stage, reducing wear on downstream cones.
3. Secondary Cone Crushing: A robust multicylinder hydraulic cone crusher (coarse chamber) reduces material to 75mm.
4. Tertiary Fine Crushing: A dedicated shorthead cone crusher with a fine chamber achieves the target product size (P80 1012mm).
5. Final Screening & Recirculation: Doubledeck vibrating screens classify product; oversize material is returned to the tertiary crusher via a closedloop conveyor.

Application Scope: Suitable for dry or wet processing of iron ore with compressive strength up to 350 MPa. Not recommended for clayrich lateritic ores without a prewashing system.

3. CORE FEATURES

HeavyDuty Frame & Base | Technical Basis: Finite Element Analysis (FEA) optimized steel structure | Operational Benefit: Eliminates vibrationinduced misalignment during 24/7 operation | ROI Impact: Reduces structural maintenance costs by 30% over standard bolttogether frames

HighChrome Alloy Wear Liners | Technical Basis: 27% chromium content with controlled carbide structure | Operational Benefit: Extends mantle and concave life by 40% when crushing abrasive hematite | ROI Impact: Reduces annual liner replacement costs by $0.08 per ton processed

Hydraulic Tramp Release & Clearing | Technical Basis: Accumulatorbased hydraulic system with 350 bar pressure rating | Operational Benefit: Clears noncrushable material (tramp iron) in under 60 seconds without manual intervention | ROI Impact: Prevents catastrophic shaft damage, saving $25,000+ per incident

Variable Frequency Drive (VFD) Feed Control | Technical Basis: Closedloop PID control on apron feeder speed | Operational Benefit: Maintains consistent crusher cavity level, preventing choke feeding or starvation | ROI Impact: Improves energy efficiency by 12% and reduces recirculating load by 8%

Integrated Dust Suppression System | Technical Basis: Dry fog nozzle array at transfer points and crusher discharge | Operational Benefit: Meets OSHA PEL for respirable crystalline silica (<50 µg/m³) | ROI Impact: Avoids regulatory fines and reduces water consumption by 70% vs. traditional spray bars

White Label Compatibility | Technical Basis: Neutral branding with OEMgrade documentation and CE/ASME certification | Operational Benefit: Allows your company to market the plant under your own brand without IP conflicts | ROI Impact: Eliminates brand premium costs, saving 812% on total procurement

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Mobile Plant) | White Label Iron Ore Solution | Advantage (% Improvement) |
| : | : | : | : |
| Throughput (tph) | 250300 tph (wet ore) | 350400 tph (consistent) | +33% |
| Wear Life (Mantle) | 8001,000 hours | 1,4001,600 hours | +60% |
| Energy Consumption (kWh/t) | 0.85 1.10 kWh/t | 0.65 0.80 kWh/t | 24% |
| Product Fines Control (5mm) | 2530% | 1822% | 27% (less slime) |
| Mean Time Between Failures (MTBF) | 120 hours | 240 hours | +100% |
| Lead Time (Bulk Order, 5 units) | 1620 weeks | 1012 weeks | 37% |

Field data from 12month trial at a Brazilian iron ore mine (Itabira region).

5. TECHNICAL SPECIFICATIONS

| Parameter | Specification |
| : | : |
| Model Capacity | 350400 tph (based on feed density 2.6 t/m³) |
| Feed Opening (Primary) | 1,200mm x 900mm |
| Max Feed Size | 1,000mm (primary) |
| Product Size (P80) | 1012mm (adjustable via CSS) |
| Total Installed Power | 650750 kW (including conveyors and screens) |
| Power Requirement | 3Phase, 480V / 60Hz (or 380V / 50Hz) |
| Main Crusher Motor | 250 kW (secondary), 220 kW (tertiary) |
| Material Specifications | Manganese steel (Mn14Cr2) for jaw; Highchrome (27% Cr) for cones |
| Physical Dimensions (L x W x H) | 28m x 12m x 8m (stationary layout) |
| Total Weight | 185,000 kg (approx.) |
| Environmental Operating Range | 10°C to 45°C; suitable for high humidity (up to 95% RH) |

6. APPLICATION SCENARIOS

Iron Ore Mine Expansion (Western Australia) | Challenge: Existing mobile plant could not handle increased feed rate of 400 tph from new pit; frequent conveyor belt tears from sharp ore. | Solution: Installed two whitelabel stationary plants with reinforced belt scrapers and highchrome liners. | Results: Throughput increased to 380 tph consistently; belt replacement interval extended from 6 weeks to 18 weeks; annual maintenance cost reduced by $240,000.

Greenfield Beneficiation Plant (India) | Challenge: Engineering contractor needed a branded solution for a 2 MTPA project but faced 6month lead times from major OEMs. | Solution: Bulk order of 4 whitelabel plants with customized electrical panels for local grid compliance. | Results: Project completed 8 weeks ahead of schedule; client saved 14% on capital equipment costs compared to branded alternatives.

Wet Season Processing (Brazil) | Challenge: High moisture content (810%) caused blinding on standard screen decks and clogging in cone crushers. | Solution: Supplied whitelabel plants with polyurethane screen media and hydraulic anticlogging system on tertiary crusher. | Results: Production downtime during rainy season reduced by 55%; product moisture content maintained below 6%.

7. COMMERCIAL CONSIDERATIONS

Equipment Pricing Tiers (Bulk Order, 5+ Units):

• Standard Package: $1.8M $2.2M per plant (includes primary, secondary, tertiary crushers, screens, conveyors, and basic electrical control panel).
• Premium Package: $2.4M $2.8M per plant (adds VFD drives, dust suppression system, remote monitoring SCADA interface, and highchrome liners).
• Custom Package: Quoted per project (includes sitespecific civil engineering, integrated stockpile management, and specialized wear liners for extreme abrasion).

Optional Features:

• Automated lubrication system: +$45,000
• Magnetic separator (for magnetite recovery): +$120,000
• Extended warranty (5 years / 20,000 hours): +8% of base price

Service Packages:

• Basic: 2year parts warranty + remote technical support
• Advanced: Onsite commissioning engineer (4 weeks) + 3year wear parts guarantee
• Full Turnkey: Civil design, installation supervision, and operator training (8 weeks)

Financing Options:

• Net 30/60 terms for approved buyers
• Leasing options available (35 year terms) with buyout at 10% residual value
• Volume discounts: 5% off for orders of 5+ units; 10% off for 10+ units

8. FAQ

Q: Can this whitelabel plant handle highsilica iron ore (SiO2 > 15%) without excessive wear?
A: Yes. The standard configuration includes highchrome liners (27% Cr) for secondary and tertiary cones. For silica content above 20%, we recommend upgrading to ceramic composite liners, which field data shows extends wear life by an additional 35%.

Q: What is the typical lead time for a bulk order of 5 units?
A: Standard lead time is 1012 weeks from receipt of purchase order and 30% deposit. This includes factory acceptance testing (FAT) and documentation. Expedited delivery (8 weeks) is available with a 5% surcharge.

Q: How does the whitelabel branding work legally?
A: We provide the plant with neutral paint (your specified RAL color), blank nameplates, and OEMgrade manuals in your company name. All CE, ASME, or local certifications are issued under your brand. We retain no visible trademarks.

Q: What is the minimum order quantity for a whitelabel configuration?
A: The minimum for a fully customized whitelabel build is 2 units. For singleunit orders, we offer a semiwhitelabel option (neutral branding but standard documentation).

Q: Can this plant be integrated with an existing wet magnetic separation circuit?
A: Yes. The plant includes a bypass chute and conveyor interface points for feeding directly into a drum magnetic separator. We can preconfigure the electrical control system to synchronize with your existing PLC.

Q: What is the expected annual maintenance cost for a 400 tph plant?
A: Based on 6,000 operating hours per year, budget $180,000 $220,000 for wear parts (liners, screens, belts) and $40,000 $60,000 for labor and consumables. This is approximately $0.09 $0.12 per ton processed.

Q: Do you provide onsite training for plant operators?
A: Yes. Our commissioning package includes a 5day operator training program covering startup procedures, liner changeout protocols, and troubleshooting common issues like tramp iron events and screen blinding.