1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, the crushing and screening circuit is often the bottleneck where inefficiencies compound. Common challenges include:
Unscheduled Downtime: Component failures in critical crushers or screeners halt entire lines, costing thousands per hour in lost production and labor.
Inconsistent Product Gradation: Outofspec aggregate leads to material rejection, reprocessing costs, and damaged client relationships.
High Maintenance Overheads: Frequent bearing changes, wear part replacement, and complex servicing schedules consume both budget and maintenance crew hours.
Inefficient Material Flow: Poorly matched crushing stages and screening units create choke points or underutilization, limiting total plant throughput.
Rising Energy Costs: Older, mechanically inefficient equipment operates as a fixed highcost center, insensitive to fluctuating material hardness or feed rates.

How do you transform this vital link from a cost center into a reliable, profitprotecting asset? The answer lies in specifying modern, integrated wholesale crushing and screening equipment designed for total cost of ownership.

2. PRODUCT OVERVIEW

This product line encompasses a complete range of primary, secondary, and tertiary crushers (jaw, cone, impact) coordinated with vibrating screens (horizontal, inclined, banana) available for wholesale procurement. The operational workflow is engineered for continuous material processing:

1. Primary Reduction: ROM (RunofMine) or quarryrun material is reduced to a manageable size by a robust primary crusher.
2. Primary Screening: Material is sized on a heavyduty screen; oversize is recirculated or sent to secondary crushing.
3. Secondary/Tertiary Crushing: Cone or impact crushers further reduce material to precise dimensions for final product specifications.
4. Final Screening & Sorting: Multipledeck screens accurately separate crushed material into defined product fractions (e.g., aggregates, chips, fines).
5. Stockpiling & Recirculation: Onspec material is conveyed to stockpiles; offspec material is automatically rerouted for further processing.

Application Scope: Stationary plants for highvolume quarry operations, semimobile setups for multisite mining projects, and trackmounted mobile units for contract crushing and recycling applications.

Key Limitations: Maximum feed size and hardness are defined by primary crusher selection; final product shape may be influenced by crusher type (e.g., impact vs. cone); extreme ambient conditions may require specific optional packages.

3. CORE FEATURES

Advanced Chamber Geometry | Technical Basis: Optimized nip angle and crushing cavity profile | Operational Benefit: Increases throughput by up to 10% while producing a more consistent particle shape with fewer flaky aggregates | ROI Impact: Higher yield of premiumpriced products and reduced recirculating load lowers cost per ton.

Hybrid Energy Drive System | Technical Basis: Direct hydraulic drive coupled with variable frequency drives (VFD) on conveyors and screens | Operational Benefit: Enables soft starts, reduces peak electrical loads by approximately 15%, and allows finetuning of speed to exact feed conditions | ROI Impact: Direct reduction in kWh consumption per ton processed and decreased demand charges from utilities.

Unified PLC Control & Telematics | Technical Basis: Centralized programmable logic controller with IoTenabled remote monitoring | Operational Benefit: Operators can adjust settings from a single location; maintenance receives realtime alerts on wear part status and performance anomalies | ROI Impact: Reduces troubleshooting time by an estimated 30% and enables predictive maintenance scheduling to avoid catastrophic failures.

QuickWear Part ChangeOut Design | Technical Basis: Hydraulic adjustment systems and bolted/wedgelocked components with toolfree access points | Operational Benefit: Liner changes on critical crushers can be completed in hours instead of shifts; screen deck panel replacement time is cut significantly | ROI Impact: Maximizes plant availability (uptime) directly translating to higher annual production volumes from the same asset base.

HeavyDuty Vibrating Mechanism | Technical Basis: HighGforce exciters mounted on subframes isolated from the main structure | Operational Benefit: Maintains aggressive material stratification even with sticky or damp feeds; transmits less vibration stress to the plant structure itself | ROI Impact: Extends structural life of support steelwork reduces longterm repair costs maintains screening efficiency in adverse conditions protecting product quality.

Integrated Dust Suppression & Noise Abatement | Technical Basis: Factoryinstalled spray bar manifolds at transfer points acoustic encapsulation packages| Operational Benefit: Simplifies compliance with site environmental health regulations from day one minimizes water usage through targeted application| ROI Impact Avoids costly retrofitting delays project permitting facilitates operation in noisesensitive areas expanding potential contract opportunities

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Wholesale Crushing & Screening Solution | Documented Advantage |
| : | : | : | : |
| Crusher Liner Life (Abrasive Rock) | 450500 kTonnage | 550600 kTonnage | +1520% improvement |
| Screening Efficiency (MidSize Fraction) ~85% ~92% +7 percentage points |
| Specific Energy Consumption kWh/tonne Varies by rock type Up to 12% reduction Achieved via hybrid drive optimization |
| Mean Time Between Failure (Critical Path) ~1 200 hours ~1 500 hours +25% improvement in reliability |
| Total Cost of Ownership (5Year Estimate) Baseline Our solution Field data indicates 812% lower TCO |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable plants from 200 tonnes per hour (tph) to over 1 500 tph depending on model selection feed material
Power Requirements: Primary plant electrical demand typically ranges from 300 kVA to 1 MVA; all major drives are compatible with global voltage standards (400V/50Hz 6kV/60Hz)
Material Specifications: Crusher mantles concaves jaws fabricated from B3/B4 grade manganese steel; screen decks available in hightensile harp wire rubber polyurethane
Physical Dimensions (Example SemiMobile Plant): Approximate footprint of 40m L x22m W x15m H; designed for modular disassembly into standard shipping containers
Environmental Operating Range: Standard units rated for 20°C to +45°C ambient temperature; optional packages available for extreme cold (40°C) or hot dusty (+55°C) environments

6. APPLICATION SCENARIOS

Granite Quarry Expansion Challenge A major aggregate producer needed to increase finished product output by without expanding their permitted footprint or adding significant labor Solution Implementation of a new tertiary crushing circuit featuring two highefficiency cone crushers paired with a multislope banana screen replacing three older units Results Throughput increased by Plant footprint reduced allowing for larger stockpiles Product cubicity improved meeting stricter road base specifications

Urban Contract Crushing Recycling Challenge A demolition contractor faced tight urban site constraints noise dust regulations variable feed materials concrete asphalt rebar Solution Deployment of a trackmounted jaw crusher screen combination with integrated magnetic separator advanced dust suppression Results Setup time reduced from days to hours enabling more bids per season Compliance assured avoiding work stoppages Revenue stream created from cleaned recycled aggregate

7 COMMERCIAL CONSIDERATIONS

Our wholesale crushing screening equipment is offered across three primary tiers:

1. Base Configuration Tier Highvolume standardized models offering proven reliability at competitive capital cost Ideal for operators prioritizing initial investment efficiency
2. Enhanced Performance Tier Includes advanced features like hybrid drives telematics automated setting adjustment systems Targets operations focused on longterm TCO reduction
3. Fully Customized Tier Engineeredtoorder solutions integrating feeding conveying dust control systems For largescale greenfield projects requiring complete turnkey circuits

Optional features include automated lubrication systems wear part monitoring sensors climate control cabins extended warranty packages

Financing options are available including capital lease operating lease leasetoown structures tailored to match your project cash flow cycles Comprehensive service packages cover scheduled maintenance parts supply remote diagnostics

8 FAQ

What level of technical expertise is required operate this equipment The unified PLC control system simplifies operation but we recommend our certified training program for your maintenance team ensure optimal performance longevity

Can these units integrate with our existing conveying stockpiling system Yes interface engineering is standard part our presales process We design ensure compatibility optimize transfer points minimize spillage dust generation

What typical lead time delivery wholesale order Lead times vary configuration For standard Enhanced Tier plants typical lead time weeks Customized solutions require detailed engineering consultation provide specific timeline

Do you offer performance guarantees Yes we provide guaranteed minimum capacity throughput based agreed feed material specifications as part commercial proposal These are backed field test data

What spare parts inventory recommended We provide recommended critical spares list based your planned annual tonnage operational location Proximity our regional parts warehouses ensures high availability