1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a private label aggregate or construction materials business where consistent product quality, disponibilité opérationnelle, and perton cost control directly define your profitability? Sourcing crushing equipment often presents critical challenges:

Sortie incohérente & Brand Risk: Variable grain size and shape from unreliable equipment leads to offspec product, damaging your private label’s reputation and triggering rejections.
Unscheduled Downtime Costs: A primary crusher failure can idle an entire production line, costing thousands per hour in lost revenue, idle labor, and missed deliveries.
High Lifetime Operating Expenses: Frequent wear part changes, excessive energy consumption, and reactive maintenance on standard machines erode your margin over the 1015 year asset life.
Évolutivité & Flexibility Gaps: Fixedconfiguration plants struggle to adapt to changing feed material or market demand for different aggregate products, limiting business agility.

How do you secure a crushing solution that operates as a reliable, efficient extension of your brand, not a constant source of operational risk and cost? The strategic answer lies in a purposebuilt Private Label Stone Crusher Plant.

2. APERÇU DU PRODUIT

UN Private Label Stone Crusher Plant is a complete, modular crushing and screening system manufactured to your exact brand specifications and performance requirements. It is not simply a rebadged standard model, but an engineered solution where every component is selected and integrated to optimize your specific feed material and output goals.

Flux de travail opérationnel:
1. Réduction primaire: Matière première pour aliments des animaux (par ex., 0700mm) is consistently fed into a robust primary jaw or impact crusher for initial size reduction.
2. Concassage secondaire/tertiaire: Material is conveyed to secondary cone or impact crushers for further refinement, producing precisely shaped intermediate aggregates.
3. Precise Screening & Classification: Multipledeck vibrating screens accurately separate crushed material into designated product fractions (par ex., 05mm, 510mm, 1020mm).
4. Stockage & Recirculation: Onspec material is conveyed to stockpiles. Oversize material is automatically recirculated back into the circuit for recrushing, ensuring maximum yield and efficiency.

Champ d'application & Limites:
Portée: Ideal for medium to largescale production of aggregates for readymix concrete, asphalte, base de route, ballast ferroviaire, and construction projects. Suited for limestone, granit, basalte, gravier de rivière, et béton recyclé.
Limites: Not designed for metallic ore processing or extremely abrasive/highsilica content materials without specific metallurgical configurations. Maximum feed size and hardness are defined during the engineering phase.

3. CARACTÉRISTIQUES PRINCIPALES

Custom Engineered Circuit Design | Base technique: Dynamic flow simulation & kinematic crusher modeling | Avantage opérationnel: Optimal crusher selection and screen deck configuration ensures firstpass yield exceeds 85%, reducing recirculating load and wear | Impact sur le retour sur investissement: Lower energy cost per ton and reduced wear part consumption by an estimated 1525%.
Unified PLC Control System with Branded HMI | Base technique: Centralized programmable logic controller with custom graphical interface | Avantage opérationnel: Your operators manage the entire plant from a single, intuitive panel displaying your logo; enables precise calibration for different product recipes | Impact sur le retour sur investissement: Reduces startup/washout time by up to 30% and minimizes operator error.
HeavyDuty Modular Chassis | Base technique: Analyse par éléments finis (FEA) optimized steel structures with highstress reinforcements | Avantage opérationnel: Provides exceptional stability under full load vibration, extending structural life and maintaining precise alignment of conveyors and crushers | Impact sur le retour sur investissement: Élimine les réparations structurelles coûteuses; enables future relocation or expansion with minimal downtime.
Premium Component Standardization | Base technique: Strategic specification of globally sourced bearings, moteurs, driveshafts & hydraulic components from Tier1 suppliers | Avantage opérationnel: Augmente le temps moyen entre les pannes (MTBF); simplifies maintenance inventory with common parts across multiple crushers/screens | Impact sur le retour sur investissement: Reduces parts stocking costs by ~20% and improves maintenance efficiency.
Suppression de la poussière intégrée & Réduction du bruit | Base technique: Encapsulated transfer points with spray nozzles & acoustic dampening panels | Avantage opérationnel: Maintains compliance with increasingly strict site environmental regulations without requiring extensive external retrofit | Impact sur le retour sur investissement: Avoids project delays or fines; improves community relations for urban/periurban sites.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | Private Label Stone Crusher Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Cohérence du produit (Shape Index) | Variable; dependent on feed fluctuation & état d'usure. | Consistent cubicity maintained via optimized cavity design & controlled feed rates. | Jusqu'à 40% more uniform product based on field particle shape analysis. |
| Disponibilité opérationnelle (Heures programmées) | ~8590%, factoring in unscheduled mechanical stops. | Targets >94%, achieved via overspec components & predictive maintenance design. | 59% increase in productive hours annually. |
| Consommation d'énergie (kWh/tonne) | Fixed speed drives; less optimized crushing chamber geometry.| Variateurs de fréquence (VFD) on feeders/conveyors & efficiencytuned crushers.| Des réductions documentées de 1018% in specific energy consumption. |
| Durée de vie des pièces d'usure (Manganese Tons/Set)| Standard manganese steel grades; generic cavity profiles.| Applicationspecific manganese alloys & computerdesigned liner profiles.| Des augmentations de 2035% en fonction de l'abrasivité du matériau. |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 150 à 600+ tonnes par heure (TPH), depending on final circuit design.
Exigences d'alimentation: Total installed power typically between 350kW 800kW; supplied for 50Hz or 60Hz operation at voltages up to the customer specification.
Spécifications matérielles: Primary frame constructed from S355JR structural steel; wear surfaces utilize Hardox® or equivalent abrasionresistant steel; Crusher jaws/mantles in premium Mn18Cr2 or Mn22Cr2 alloy.
Dimensions physiques: Modular design allows transport within standard shipping containers; assembled plant footprint is customized per layout but designed for compactness.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust emission levels can be configured to meet sub10 mg/Nm³ standards.

6. SCÉNARIOS D'APPLICATION

Private Label Aggregate Producer for National Retail Chain

Défi: A supplier needed to produce six distinct decorative landscape aggregates under its own brand for a major retailer but faced high reject rates due to inconsistent sizing from aged equipment.
Solution: Implementation of a tailored private label stone crusher plant featuring a tertiary cone crusher circuit with specialized screening decks calibrated for each product SKU.
Résultats: Product consistency achieved >98% compliance with retailer specifications on all lines within one month of commissioning.

Municipal Road Base Production Contractor

Défi: A contractor operating multiple public works projects required mobile crushing capacity but could not afford the downtime associated with moving and repermitting separate units at each site.
Solution: A semimobile private label plant on a trailerized chassis was deployed as their dedicated asset across all city contracts over three years.
Résultats: Reduced mobilization time between sites by over twothirds due to preapproved permits based on standardized environmental controls.

7 CONSIDÉRATIONS COMMERCIALES

Our private label stone crusher plants are offered under transparent pricing tiers based on capacity complexity:

1\. Base Plant Tier (Up To ~250 TPH): Includes primary jaw secondary impactor basic screening module core conveyors PLC control system Warranty starts at [Price Range Estimate]
2\. HighCapacity Tier (~251–500 TPH): Adds tertiary crushing stage advanced multideck screening dust suppression package heavyduty feeders
3\. Custom Integrated Tier (500+ TPH): Fully engineered circuit including automated product switching advanced telemetry remote monitoring capabilities

Les fonctionnalités optionnelles incluent:
Systèmes automatisés de lubrification à la graisse
Tramp metal detection/autoreject systems
Ensembles de production d'énergie embarqués
Extended warranty/service plans covering parts labor

Options de financement:
We work with international export credit agencies project finance partners offer flexible leasetoown structures typical terms ranging months

8 FAQ

Q1 How do you ensure the plant will perform with our specific rock type?
A1 Our engineering process begins with detailed analysis of your feed material samples including crushability work index abrasiveness We use this data calibrate our simulation models provide guaranteed performance metrics before fabrication

Q2 What level branding customization possible?
A2 Full exterior branding control panel graphics documentation provided You also receive technical documentation branded manuals spare parts lists under your company name

Q3 How does implementation affect our current production schedule?
A4 Plants are preassembled tested at our facility prior shipment minimizing onsite commissioning time typically weeks not months minimizing disruption

Q4 What ongoing technical support available?
A4 We offer tiered service packages from basic remote troubleshooting comprehensive annual maintenance contracts including regular inspections wear part optimization recommendations

Q5 Are these plants suitable regions strict environmental noise regulations?
A5 Yes they can specified include comprehensive enclosures baghouse filter systems sound dampening packages designed meet stringent EU US standards

Q6 Can plant expanded later increased capacity?
A6 The modular design inherently allows addition extra crushing stages larger screens extended conveyor systems planned during initial design phase facilitates costeffective future expansion