1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are escalating operational costs and unpredictable availability eroding your aggregate production margins? Pour les directeurs d’usine et les entrepreneurs en ingénierie, the core challenges of a stone crusher plant often center on three critical areas:

Temps d'arrêt imprévus: Pannes de roulements, component wear, and unexpected breakdowns halt your entire production line. Industry data indicates that for a midsized quarry, every hour of crusher downtime can result in over $1,000 in lost revenue and idle labor.
Sortie incohérente & Qualité: Fluctuations in feed size or material hardness lead to variable final product gradation, failing to meet strict project specifications and resulting in rejected loads or costly reprocessing.
High Operational Expenditure: Soaring energy consumption from inefficient crushing chambers, combined with the frequent need for manual adjustment and highcost replacement parts for wear components, directly impacts your costperton metric.

Is your current crushing solution a constant source of reactive maintenance and financial leakage? What if you could implement a plant engineered from the outset for durability, efficacité, and predictable operation?

2. APERÇU DU PRODUIT: ODM STONE CRUSHER PLANT

Our ODM Stone Crusher Plant is a stationary or semimobile crushing circuit engineered for highvolume production of aggregates (05mm, 520mm, 2040mm) from primary rock types like granite, basalte, calcaire, et pierre de rivière.

Flux de travail opérationnel:
1. Concassage primaire: Dump feed is reduced by a robust jaw crusher or gyratory crusher to a manageable size (typiquement <250mm).
2. Secondaire & Concassage Tertiaire: Material is conveyed to cone crushers or impact crushers for further size reduction and shaping to meet required specifications.
3. Dépistage & Classification: Les tamis vibrants séparent les matériaux concassés en fractions précises du produit; oversize material is recirculated back to the appropriate crusher.
4. Manutention des matériaux: A network of conveyors efficiently moves material between stages and to final stockpiles.

Champ d'application & Limites:
Portée: Ideal for largescale quarry operations, projets d'infrastructures (road/highway construction), commercial concrete batching plants, and railway ballast production requiring consistent output from 150 à 800+ TPH.
Limites: Not designed for processing highly abrasive ores (par ex., taconite) without specific liner configurations. Maximum feed size is determined by the primary crusher model selected.

3. CARACTÉRISTIQUES PRINCIPALES

Conception de cadre modulaire | Base technique: Préconçu, bolttogether heavyduty steel structure | Avantage opérationnel: Réduit le temps d'installation du site jusqu'à 30% versus welded designs; permet une future reconfiguration ou un déménagement de l'usine | Impact sur le retour sur investissement: Lower capital installation costs and preserved asset flexibility extend plant lifecycle value.

Intelligent Crushing Chamber Geometry | Base technique: CADoptimized liner profiles and kinematics based on feed material analysis | Avantage opérationnel: Maintains consistent cavity volume throughout the wear cycle for stable output gradation and reduced frequency of manual adjustment | Impact sur le retour sur investissement: Improves product yield within spec by an estimated 812%, reducing waste.

Système de lubrification centralisé à la graisse | Base technique: Automatisé, programmable lubrication unit with blockage detection | Avantage opérationnel: Ensures optimal bearing lubrication across all major crushers under all operating conditions; eliminates manual greasing errors and intervals | Impact sur le retour sur investissement: Field data shows a correlated 40% reduction in premature bearing failures, directly lowering parts costs and downtime.

PLCBased Process Control & Surveillance | Base technique: Automate programmable industriel avec interface homme-machine (IHM) displaying amperage, pression, température | Avantage opérationnel: Operators can monitor plant health in realtime; automated safety interlocks prevent catastrophic damage from tramp metal or overloads | Impact sur le retour sur investissement: Enables predictive maintenance scheduling and protects major components from avoidable failure.

HighStrength AbrasionResistant Steel Components | Base technique: Use of AR400/500 steel in hoppers, chutes, and skirting at highwear points | Avantage opérationnel: Significantly extends service life in highabrasion transfer zones compared to mild steel; reduces frequency of patching and replacement | Impact sur le retour sur investissement: Lowers longterm maintenance material costs and associated labor.

Tier4 Final / EU Stage V DieselElectric Option | Base technique: Diesel generator set powering allelectric drives on conveyors and screens | Avantage opérationnel: Provides full operational mobility without reliance on grid power; meets global emissions standards for flexible deployment | Impact sur le retour sur investissement: Eliminates costly grid connection in remote sites while maintaining environmental compliance.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Our ODM Stone Crusher Plant Solution | Avantage documenté |
| : | : | : | : |
| Overall Mechanical Availability (Annuel) | 90 92% | >95% Target Design Standard| +3% à +5% Amélioration |
| Consommation d'énergie par tonne traitée (kWh/t) Varie selon le type de roche. Baseline = Limestone. Industry average derived from published case studies.| ~0.8 1.0 kWh/t| Optimized drive packages aim for ~0.7 0.9 kWh/t| Up to ~12% Reduction |
| Wear Life of Primary Jaw Liners (Granit abrasif) Mn18Cr2 standard castings.| ~120,000 tons| Premium Mn22Cr2 optional liners target ~150,000 tons| +25% Improvement Available |
| Temps moyen entre les pannes (MTBF) Major Drives & Bearings Based on historical service data across comparable installations.| ~4,500 hours| Design targets >6,000 hours through superior sealing/lubrication systems.| +33% Improvement Target |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 150 TPH à 800+ TPH nominal capacity.
Exigences d'alimentation: Total connected load typically between 400kW 1200kW depending on configuration. Options include direct grid connection (380V/50Hz ou 480V/60Hz) or integrated dieselelectric power pack.
Spécifications matérielles: Primary structures fabricated from Q345B steel; highwear areas utilize AR450 abrasionresistant steel liners; crusher frames are highgrade cast steel or fabricated alloy steel.
Dimensions physiques (Exemple de configuration): A typical threestage plant footprint may approximate 65m (L) x 45m (W) x 18m (H). La conception modulaire permet une adaptation aux contraintes du site.
Plage de fonctionnement environnementale: Designed for ambient temperatures from 20°C to +45°C with optional coldweather or dustsuppression packages available.

6. SCÉNARIOS D'APPLICATION

Highway Construction Project – Remote Location

Défi: A contractor needed consistent Class I & II aggregates for a new highway section with no local grid power access. High mobilization/demobilization speed was critical due to tight project timelines.
Solution: Implementation of a semimobile ODM Stone Crusher Plant with integrated Tier4 Final diesel power pack and three crushing stages.
Résultats: The plant was commissioned within one week of arrival on site. It achieved an average output of 320 TPH meeting all gradation specs without reliance on external utilities.

Agrandissement de la carrière de granit commercial

Défi: An existing quarry faced declining product quality consistency due to an aging secondary/tertiary circuit leading to excessive recirculating load (~40%) energy waste.
Solution: Replacement of the old tertiary cone crushers with new models featuring intelligent chamber geometry within an optimized ODM circuit layout.
Résultats: Recirculating load decreased to approximately 28%. This improved net throughput by 15% while reducing specific energy consumption by an estimated 9%, enhancing overall margin per ton processed.

7 CONSIDÉRATIONS COMMERCIALES

Our ODM Stone Crusher Plants are offered under clear commercial frameworks:

Niveaux de tarification: Pricing scales according to capacity throughput design complexity:
Tier I Basic Configuration Standard duty primary jaw secondary cone basic screening
Tier II Enhanced Configuration Heavy duty primary premium cone multi stage screening dust suppression
Tier III Custom Turnkey Solution Full electrical automation remote monitoring advanced environmental controls

Optional Features Premium wear liners automatic level sensors magnetic separators sound attenuation enclosures extended walkways service platforms

Forfaits de services disponibles:
Basic Warranty Coverage standard parts labor warranty period
Annual Maintenance Contract scheduled inspections preventive maintenance parts discounts
Full Service Agreement includes guaranteed availability performance metrics consumables management

Financing Options We work with international export credit agencies equipment finance partners offer competitive leasing rental purchase structures suit project cash flow requirements

8 FAQ

Q What level foundation preparation required?
A Detailed civil engineering drawings provided require stable compacted ground minimal concrete foundations modular design reduces concrete volume versus traditional plants

Q How does ensure compatibility existing equipment?
A Our engineering team conducts pre sale review proposed layout feed characteristics can adapt transfer points conveyor lengths integrate certain existing units like primary screens

Q What typical lead time delivery commissioning?
A For standard configurations lead time ranges months ex works Site commissioning supervised our engineers typically requires weeks depending complexity includes operator training

Q Les pièces de rechange sont-elles facilement disponibles à l'échelle internationale?
A We maintain global network certified warehouse partners provide genuine spare parts support Critical wear items commonly stocked ensure minimal logistics delay

Q Can operate extreme cold climates?
A Yes optional packages include heated lube oil systems cold start battery packages insulated piping enclosures critical components ensure reliable operation sub zero temperatures

Q What process guarantee product gradation?
A While final gradation depends feed material characteristics we provide performance guarantees overall throughput mechanical availability based agreed test protocols commissioning

Q Do offer financing large capital purchases?
A Yes we have established relationships several international finance institutions assist structuring purchase lease arrangements improve project economics