1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent les marges de votre projet? For plant managers and contractors overseeing bulk material processing, inefficient crushing and screening is a primary bottleneck. Les défis courants incluent:
High PerTon Cost: Inefficient flow, excessive recirculation, and frequent component wear directly increase your cost per ton of processed material.
Temps d'arrêt imprévus: Unplanned stops for maintenance, blocages, or mechanical failures disrupt entire production schedules, causing significant revenue loss.
Gradation du produit incohérente: Offspec material results in product rejection, frais de retraitement, et des clients mécontents.
Rising Labor & Intensité énergétique: Equipment requiring constant monitoring, réglage manuel, or excessive power consumption drives up operational expenditures.
Limites d'évolutivité: Fixed systems struggle to adapt to changing feed material or required product specifications, limiting contract flexibility.

Is your current setup equipped to maximize throughput while controlling these variables? A strategic investment in modern exportgrade crushing and screening equipment is not merely a capital purchase; it is a direct intervention on your bottom line.

2. APERÇU DU PRODUIT

Cette gamme de produits englobe les poids lourds, containerized crushing and screening plants engineered for highvolume primary, secondaire, and tertiary processing of aggregates, minerai, et minéraux industriels. Designed for export and demanding site conditions, these systems transform raw feed into precisely graded end products.

Flux de travail opérationnel:
1. Réduction primaire: Raw feed is introduced to a robust jaw or gyratory crusher for initial size reduction.
2. Dépistage primaire & Convoyage: Crushed material is conveyed to a primary screen deck where subsize product is separated; oversize is routed for further crushing.
3. Traitement secondaire/tertiaire: Oversize material is directed to cone or impact crushers for additional reduction in closedcircuit with screening units.
4. Final Product Sorting: Multiple deck screens separate the processed material into 35 specified final product fractions.
5. Stockage: Finished products are conveyed to designated stockpiles or loading areas.

Champ d'application: Ideal for largescale quarrying, préconcentration minière, grands projets d'infrastructures (base de route, ballast ferroviaire), and commercial aggregate production.
Principales limites: Not suitable for ultrafine grinding (sub5mm) without specialized circuits; maximum feed size and hardness are defined by modelspecific engineering limits.

3. CARACTÉRISTIQUES PRINCIPALES

Géométrie de chambre avancée | Base technique: Angle de pincement et profil de cavité de concassage optimisés | Avantage opérationnel: Increases firstpass reduction ratio, minimizing recirculating load and wear on downstream components | Impact sur le retour sur investissement: Reduces energy consumption per ton by up to 15% and extends liner life

Centralized Grease Automation | Base technique: Programmable, highpressure centralized lubrication system | Avantage opérationnel: Ensures consistent bearing lubrication under all load conditions without manual intervention | Impact sur le retour sur investissement: Lowers bearing failure risk by an estimated 70%, directly preventing costly unscheduled downtime

Flexibilité de la puissance hybride | Base technique: Configurable power train accepting grid connection or onboard dieselgenerator sets | Avantage opérationnel: Enables rapid deployment to remote sites and provides operational resilience during grid instability | Impact sur le retour sur investissement: Eliminates infrastructure delays; les données de terrain montrent un 40% reduction in site commissioning time

Modular Component Design | Base technique: Bolttogether substructures with standardized interfaces | Avantage opérationnel: Simplifies transport in standard containers and allows for strategic component replacement or future circuit reconfiguration | Impact sur le retour sur investissement: Cuts international shipping costs by approximately 25% versus monolithic units

Intelligent Process Control (IPC) Système | Base technique: PLCbased system with load management and CSS adjustment capabilities | Avantage opérationnel: Automatically regulates feed rates and crusher settings to maintain optimal throughput and product gradation | Impact sur le retour sur investissement: Maintains consistent spec yield (>98%), reducing waste and reprocessing

HeavyDuty Vibrating Screen with Deck Access System | Base technique: High Gforce exciters mounted on reinforced decks with walkways | Avantage opérationnel: Provides efficient material stratification and sizing even with sticky or damp feed; allows safe, quick media changes | Impact sur le retour sur investissement: Improves screening efficiency by 20%, boosting overall plant capacity

Suppression de la poussière intégrée & Réduction du bruit | Base technique: Spray bar systems at transfer points with acoustic encapsulation panels | Avantage opérationnel: Meets stringent international environmental compliance standards for particulate matter and noise pollution | Impact sur le retour sur investissement: Mitigates project delay risks from regulatory noncompliance and community complaints

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Notre concassage & Solution de dépistage | Avantage (% amélioration) |
|||||
| Tonnes par heure (TPH) / kW | Varie selon l'application | Optimized flow design & conduire l'efficacité | +1015% Efficacité énergétique |
| Liner Changeout Time | 812 heures (jaw/cone) | Hydraulic adjustment & assisted tooling |35% Temps d'arrêt |
| Screening Efficiency ~8590% Patented throw & deck design +1012% Rendement |
| Temps moyen entre les pannes (Critical Bearings) ~1218 months Premium seals & grease automation +50% Durée de vie |
| OnSite Assembly Duration ~1014 days Preassembled modular skids 40% Temps de mise en service |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 300 à 1,200 tonnes métriques par heure (TPH), depending on feed material (densité apparente ~1,6 t/m³) and product gradation.
Exigences d'alimentation: Primary plant power range from 250 kVA à 800 kVA. Available as 50Hz or 60Hz compliant. Hybrid option includes integrated Stage V/Tier 4 Final diesel generators.
Spécifications matérielles: Highabrasion steel wear plates (HB400+); Crusher mantles/concaves in premium manganese steel (18%22%); Screen decks in rubberpolyurethane composite or woven wire mesh.
Dimensions physiques (Typical Primary Unit): Transportable within standard highcube containers. Assembled dimensions approx.: Length 25m x Width 7m x Height 5m.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C. Dust suppression system rated for control below 10 mg/m³ at emission points.

6. SCÉNARIOS D'APPLICATION

Granite Quarry Expansion – Southeast Asia

Challenge A quarry operation needed to increase output by 60% to fulfill a new highway contract but was constrained by space limitations and a dated twostage plant with high fines production.
Solution Implementation of a compact threestage trackmounted crushing circuit featuring an advanced cone crusher in closed circuit with a tripledeck screen.
Results The new setup achieved a 65% throughput increase within the same footprint while improving yield of valuable chip products by 22%. Payback was achieved in under 14 months through the contract fulfillment.

Iron Ore Scalping & PreConcentration – West Africa

Challenge A mining operation faced high processing costs due to transporting lowgrade waste rock through the entire primary circuit.
Solution Integration of an ultraheavyduty grizzly scalper ahead of the primary crusher station to remove barren waste rock (>250mm).
Results Field data shows over 30% of total volume was rejected at the scalp level, significantly reducing energy consumption and wear in the downstream crushing stages. This increased effective plant capacity without adding new primary crushers.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Solutions are offered across three tiers:
Standard: Highefficiency base plant for common aggregate applications.
HighAbrasion: Upgraded wear packages for abrasive feeds like granite/basalt.
MiningSpec: Reinforced structures & components for heavyfeed ore applications.

Fonctionnalités facultatives: Onboard weighing systems, systèmes automatisés de détection de métaux/de soulagement des traces,
remote telematics for performance monitoring,
extra dust encapsulation packages.

Forfaits de services: Choose from annual inspection plans,
wearsandspares contracts with guaranteed supply,
or fullsite service agreements including labor.

Options de financement: We work with export credit agencies
to provide project financing,
and offer leasetoown structures
to align payment schedules with your cash flow from project milestones.

8. FAQ

Q1 Are these plants compatible with our existing conveyors stackers?
A1 Yes within defined engineering parameters The control system can be integrated Standard discharge heights conveyor widths belt speeds are documented Our engineering team can perform a compatibility review based on your existing layout drawings

Q2 What is the expected operational impact during the transition from our old plant?
A2 With modular design the objective is minimal disruption Preassembly testing minimizes onsite commissioning A phased implementation over weeks can be planned typically allowing partial operation of your legacy system during cutover

Q3 How do you guarantee performance metrics like throughput gradation
A3 Performance guarantees are based on certified test reports using customersupplied sample materials These form part of the commercial contract Guarantees cover capacity power consumption key wear part life under defined operating conditions

Q4 What are typical lead times from order placement delivery
A4 For standard configured plants lead time ranges between months depending on model complexity Custom configurations may require additional engineering time All timelines are confirmed upon project specification

Q5 What training is provided for our operations maintenance teams
A5 Comprehensive training is included covering daily operation routine maintenance troubleshooting safety procedures Training occurs during commissioning both classroom instruction handson equipment familiarization Manuals schematics provided digitally permanently accessible