1. PAINPOINT DRIVEN OPENING

Managing an iron ore crushing circuit is a highstakes operation where efficiency directly defines profitability. Are you facing these persistent challenges?
Unscheduled Downtime: Unplanned stoppages due to tramp metal, uncrushable material, or component failure can cost over $10,000 per hour in lost production and labor.
Inconsistent Product Gradation: Fluctuations in feed size or hardness lead to offspec product, causing bottlenecks in downstream grinding and processing, reducing overall plant yield.
High Maintenance Costs & Wear: The abrasive nature of iron ore results in rapid wear of liners, blow bars, and other consumables, driving up operational expenditure and requiring frequent, laborintensive changeouts.
Energy Inefficiency: Older or improperly configured crushing stages consume excessive power per ton of material processed, a significant and growing lineitem cost.
Inflexibility to Feed Variation: Fixedspeed crushers struggle to maintain optimal performance when ore characteristics change from one pit zone to another.

How can you achieve a more predictable tonnage cost, reduce operational risk, and ensure your primary crushing stage is an asset rather than a bottleneck?

2. PRODUCT OVERVIEW: WHITE LABEL IRON ORE CRUSHING PLANT

Our solution is a configurable, white label primary and secondary crushing plant engineered specifically for hard, abrasive iron ores (Hematite, Magnetite). It is designed as a modular system for rapid deployment and integration into new or existing mineral processing circuits.

Operational Workflow:
1. Primary Dump/Fee: ROM ore is fed via haul truck or loader into a rugged grizzly feeder, which scalps out fine material and directs oversize to the primary crusher.
2. Primary Crushing: A heavyduty jaw crusher reduces the ore to a nominal 150200mm product.
3. Secondary Crushing & Screening: The primary crushed material is conveyed to a secondary cone crusher for further reduction. A closedcircuit screen ensures precise final product sizing before transfer to the next processing stage.

Application Scope & Limitations:
Scope: Ideal for greenfield sites, plant expansion projects, or replacement of aging fixed infrastructure. Suitable for production capacities from 500 to 2,500+ TPH.
Limitations: Not designed as a tertiary or fine grinding solution. Maximum feed size is limited by primary crusher opening. Plant requires stable, prepared ground for installation.

3. CORE FEATURES

Adaptive Crushing Chamber | Technical Basis: Hydroset CSS adjustment & automated control system | Operational Benefit: Operators can remotely adjust the closedside setting (CSS) in minutes to compensate for feed changes or optimize product size without stopping the crusher. | ROI Impact: Maintains target throughput and gradation, preventing downstream bottlenecks; estimated 58% yield improvement.

Tramp Metal Protection System | Technical Basis: Hydraulic overload relief cylinders with automatic reset | Operational Benefit: Instant pressure release protects crusher components from catastrophic damage caused by uncrushable steel or digger teeth. | ROI Impact: Eliminates risk of major mechanical failure and associated repair costs (often exceeding $50k) and extended downtime.

AbrasionResistant Material Package | Technical Basis: Premium manganese steel liners with optimized cavity profiles | Operational Benefit: Liners withstand extreme abrasion from silicarich iron ore, significantly extending service life between changeouts. | ROI Impact: Reduces liner consumption costs by 1525% and lowers maintenance manhours per ton crushed.

Direct Drive Crusher Technology | Technical Basis: Eliminates Vbelts and sheaves; couples motor directly to crusher | Operational Benefit: Improves power transmission efficiency (up to 99%), reduces maintenance points, and allows for variable speed control for process optimization. | ROI Impact: Lowers energy consumption by approximately 812% compared to traditional Vbelt driven systems.

Centralized Greasing & Lube System | Technical Basis: Automated singlepoint lubrication with monitoring sensors | Operational Benefit: Ensures critical bearings receive consistent lubrication without manual intervention, preventing dryrun failures. | ROI Impact: Extends bearing life by up to 40%, reducing spare parts inventory costs and unplanned stops.

Modular Walkways & Access Platforms | Technical Basis: Prefabricated bolttogether safety platforms around all service points | Operational Benefit: Provides safe, compliant access for daily inspections and routine maintenance tasks such as liner changes. | ROI Impact: Reduces safety incident risk and cuts planned maintenance time by up to 30%, increasing plant availability.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Fixed Speed/Manual) | White Label Iron Ore Crushing Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | 8590% (planned & unplanned stops) | 9396% (systemprotected operation) | +7% Improvement |
| Power Consumption (kWh/t)| Variable; often inefficient at partial load| Optimized via direct drive & variable speed control| Up to 12% Reduction |
| Liner Life (Million Tons)| Highly variable; frequent changeouts| Extended via material science & chamber design| +20% Average Increase|
| Product Gradation Consistency| Can fluctuate ±15% with feed variation| Maintained within ±5% via adaptive controls| +67% More Consistent|
| Mean Time Between Failure (MTBF)| Lower due to tramp metal damage risk| Significantly higher with integrated protection| Data shows +35% Improvement|

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 500 TPH to 2,500 TPH nominal throughput of iron ore (S.G. ~2.6 t/m³).
Primary Crusher: Heavyduty jaw crusher with feed openings up to 1,500mm x 1,200mm.
Secondary Crusher: Highcapacity cone crusher with multiple cavity options.
Power Requirements: Total installed power typically between 500 kW 1,200 kW depending on configuration; voltage customizable (e.g., 6.6 kV).
Key Material Specifications: Primary frame constructed from hightensile steel plate; liners in premium manganese steel (1822%); critical wear areas lined with AR400 steel plate.
Physical Dimensions (Modular): Modules designed for standard shipping container dimensions; overall footprint optimized per customer layout.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dust suppression system included as standard; electrical components rated for appropriate ingress protection.

6. APPLICATION SCENARIOS

Greenfield Magnetite Project

Challenge: A new mining operation required a scalable crushing solution with minimal onsite construction time due to remote location constraints. Consistent 32mm feed for downstream grinding was critical.
Solution: Implementation of a modular white label iron ore crushing plant with primary jaw and secondary cone crushers in closed circuit with a sizing screen.
Results: Plant commissioned in 60% less time vs traditional build. Achieved steadystate production of 800 TPH meeting target spec (>95% passing), enabling onschedule rampup of the concentrator.

Aging Plant Retrofit

Challenge: An existing hematite processing facility suffered from low throughput (<600 TPH) and excessive downtime in its primary section due to constant liner wear failures on old equipment.
Solution: Replacement of the legacy primary gyratory with our white label jaw crushing module as a dropin solution within the existing structure footprint.
Results: Throughput increased by over 25%. Liner changeout intervals extended from every ~800k tons to over 1 million tons reducing annual maintenance costs by an estimated $120k USD while boosting overall plant availability.

7 COMMERCIAL CONSIDERATIONS

Our white label model provides significant commercial flexibility versus branded OEM solutions:

Pricing Tiers:
Base Configuration: Includes core crushing modules (feeder/primary/secondary), walkways/platforms ladders , basic dust suppression ,and motor starters .
Optimized Configuration: Adds variable frequency drives , automated lubrication system , advanced tramp metal protection ,and PLCbased control panel .
Turnkey Configuration: Full EPC scope including structural supports conveyors electrical substation integration commissioning spares package .

Optional Features: Onboard weighing instrumentation advanced rock level sensors remote monitoring connectivity packages custom paint schemes .

Service Packages Available:
1 Annual inspection parts discount program
3 /5year comprehensive service agreements including planned maintenance wear part supply technical support

Financing Options:
Equipment leasing capital loan facilitation through partner institutions project financing support available

8 FAQ

Q What level of site preparation is required before delivery?
A The plant modules require prepared concrete foundations equivalent specifications will be provided during engineering Our team can supervise installation

Q How does this system integrate with my existing SAG/Ball mill feed conveyor?
A Our engineering team will design the discharge conveyor interface hopper ensure seamless integration into your current downstream process flow

Q Are spare parts readily available given it's a white label product?
A Yes All critical wearing parts bearings seals are standardized industrial components held global stock Major castings are sourced single certified foundry ensuring consistent supply lead times

Q What training provided our operations maintenance staff?
A We provide comprehensive onsite training covering normal operation troubleshooting routine maintenance procedures Detailed manuals schematic diagrams included

Q Can this plant handle lateritic ores sticky moisture content?
A While designed primarily hard abrasive ores we can configure specific options such as impact crushers secondary stage specialized feeder designs manage higher moisture mitigate clogging Discuss your specific feedstock during consultation

Q What typical delivery lead time after order confirmation?
A For standard configurations lead time ranges months depending final specification complexity Current project schedule will be confirmed upon quotation

Q Is performance guarantee offered?
A Yes We provide written performance guarantee covering rated throughput final product PSD specifications based agreed test protocol post commissioning