1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gérez-vous une opération de granulats à volume élevé et êtes-vous confronté à des goulots d'étranglement persistants qui érodent la rentabilité ?? Pour les directeurs d’usine et les entrepreneurs en ingénierie, the challenges of a 250300tph stone crushing plant are often quantifiable: unpredictable downtime from component failures, escalating maintenance labor costs, gradation incohérente du produit final conduisant à des charges rejetées, and the high capital risk of integrating equipment from multiple vendors. Ces problèmes ont un impact direct sur vos résultats. How do you ensure consistent throughput to meet tight project schedules? Can you reduce unplanned maintenance intervals without sacrificing capacity? Is your current setup optimized for the lowest cost per ton over a 10year lifecycle? La solution réside dans une solution entièrement intégrée, whitelabel crushing plant engineered for reliability and efficiency.

2. APERÇU DU PRODUIT

Ce produit est un complet, stationnaire White Label 250300tph Stone Crushing Plant, designed as a turnkey solution for highcapacity production of aggregates for road base, béton asphalte, et ballast ferroviaire. L'installation est configurée pour le primaire, secondaire, and tertiary crushing stages to produce precisely graded cubical aggregates.

Flux de travail opérationnel:
1. Concassage primaire des mâchoires: Matière première de grande taille (jusqu'à 750 mm) est réduit à <200mm by a robust jaw crusher.
2. Concassage secondaire à cône: Material is conveyed to a cone crusher for further reduction, façonner l’agrégat.
3. Dimensionnement & Séparation: Le matériau broyé est criblé via des tamis vibrants à plusieurs étages; onspec product is diverted to stockpiles.
4. Façonnage tertiaire (Facultatif): Oversize material is recirculated through an impact crusher (TOUT LE MONDE) for fine shaping and sand production.
5. Integrated Conveying: A network of heavyduty conveyors with centralized control manages material flow between all stages.

Champ d'application: Idéal pour les opérations de grandes carrières, grands projets d’infrastructures nécessitant une production de granulats sur place, and dedicated aggregate supply yards serving metropolitan regions.

Limites: This configuration requires stable foundational ground for installation, threephase highvoltage power supply, and is designed for mediumtohard abrasion index stones (par ex., granit, basalte). For highly mobile or frequent relocation needs, a modular skidmounted system may be more appropriate.

3. CARACTÉRISTIQUES PRINCIPALES

Unified Control System | Base technique: Automate centralisé avec interface SCADA | Avantage opérationnel: Singlepoint monitoring and control of the entire crushing circuit enables rapid adjustment of feed rates and crusher settings to maintain target gradation. | Impact sur le retour sur investissement: Reduces operator headcount requirements by up to 30% and minimizes offspec production waste.
Mangeoire vibrante robuste avec section Grizzly | Base technique: Reinforced steel plate feeder with adjustable grizzly bars | Avantage opérationnel: Assure une cohérence, regulated feed to the primary crusher while scalping out natural fines, preventing crusher choke and reducing wear on primary crushing chamber. | Impact sur le retour sur investissement: Increases primary crusher efficiency by an estimated 1520%, extending liner life.
Réglage hydraulique & Dégagement sur concasseurs | Base technique: Integrated hydraulic systems on jaw and cone crushers | Avantage opérationnel: Allows operators to adjust crusher settings or clear blockages in minutes without manual disassembly, même sous charge. | Impact sur le retour sur investissement: Cuts downtime related to chamber clearing and CSS adjustment by over 80% par rapport aux systèmes manuels.
Suppression de la poussière & Système de confinement | Base technique: Atomized spray nozzles at transfer points with encapsulation skirts | Avantage opérationnel: Réduit considérablement les particules en suspension dans l'air, veiller au respect de la réglementation environnementale et améliorer les conditions de travail sur les chantiers. | Impact sur le retour sur investissement: Mitigates risk of regulatory fines and reduces healthrelated absenteeism among personnel.
HighCapacity Conveyor Design | Base technique: Oversized idlers, lits d'impact aux points de chargement, et variateurs de fréquence (VFD) | Avantage opérationnel: Handles peak loads without spillage or belt damage; VFDs allow soft starts and optimized power consumption matched to actual load. | Impact sur le retour sur investissement: Extends conveyor belt life by approximately 40% and reduces energy consumption of the conveying system.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Configuration typique) | White Label 250300tph Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité des installations | ~7580% (due to component mismatch & temps d'arrêt) | 92%+ (engineered integration & reliability focus) | 1520% Amélioration |
| Coût par tonne (Entretien)| Based on disparate part sourcing & heures de travail| Consolidated service contracts & common parts inventory| Jusqu'à 25% Réduction |
| Cohérence de la gradation du produit| Varies due to independent process stages| Tight control via integrated process logic & feedback| Variability Reduced by ~30% |
| Installation & Temps de mise en service| 812 semaines (multivendor coordination)| 56 semaines (singlesource responsibility)| Time Savings of ~40% |
| Consommation d'énergie (kWh/tonne)| Baseline from nonoptimized systems| Optimized motor selections & conveyor VFDs| Estimé 1015% Économies |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de débit conçue: 250 300 tonnes métriques par heure (tph) of crushed stone aggregate, en fonction de la dureté du matériau alimenté (<180 MPa recommandé) and required final product size.
Exigences d'alimentation: Puissance totale installée environ 550 650 kW. Requires primary supply voltage of 10kV or transformable medium voltage supply.
Spécifications des matériaux clés:
Plaques à mâchoires du concasseur primaire / Doublures de cône: Acier à haute teneur en manganèse (Mn18Cr2).
Plateformes d'écran: Harp wire or polyurethane modular panels.
Bande transporteuse: EP630/4 minimum rating with top cover ≥10mm.
Structural Steel Frame: S355JR grade painted with industrial epoxy system.
Empreinte approximative: ~75m L x 45m W x 15m H (hors stocks). Foundation design loads provided upon geotechnical survey.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C avec des packs de chauffage/refroidissement en option pour les climats extrêmes.

6. SCÉNARIOS D'APPLICATION

Large Limestone Quarry Expansion

Challenge A quarry supplying regional concrete plants needed to increase output but was constrained by an aging twostage plant causing excessive fines production (>25%) in the target 57 stone specification.

Solution Implementation of this whitelabel threestage plant featuring a cone crusher in closed circuit with sizing screens followed by a tertiary impactor for reshaping oversize.

Results Final product yield in the target 57 specification increased from ~65% to over 88%, while overall plant throughput stabilized at a sustained rate of >280 tph.

Grand projet de construction d’autoroute

Challenge A contractor on a remote highway corridor faced prohibitive costs of transporting aggregates over long distances and needed reliable onsite production meeting strict DOT gradation controls.

Solution Deployment of this preengineered whitelabel crushing plant configured specifically for highabrasion basalt feed from the project's borrow pit.

Results The project achieved selfsufficiency in aggregate supply within eight weeks of equipment delivery; consistent gradation compliance eliminated any load rejections at the asphalt mixing plants along the corridor.

Aggregate Recycling Operation

Challenge An urban recycling center processing demolished concrete sought highervalue products but struggled with contamination removal in their singlestage setup.

Solution Integration of this plant's heavyduty feeder/grizzly section combined with an electromagnetic separator over the primary conveyor before secondary crushing stages.

Results Contaminant removal efficiency improved from ~70% to >95%, allowing production of clean RCA meeting DOT Class II specifications at volumes exceeding >260 tph processed C&D déchets

CONSIDÉRATIONS COMMERCIALES

The capital investment for a whitelabel stone crushing plant solution varies based on configuration depth:

Niveaux de tarification:
Tier I Base Plant Includes primary jaw secondary cone screening towers main conveyors central control cabin electrical package $1M $1M
Tier II Enhanced Plant Adds tertiary shaping VSI advanced dust suppression system automated lubrication system $1M $1M
Tier III Turnkey Package Includes full civil engineering drawings erection supervision commissioning training extended warranty $1M+

Fonctionnalités facultatives:
Onboard power generation package automated metal detection magnetic separation systems remote telematics monitoring additional stockpile conveyors

Forfaits de services:
Standard hours onsite commissioning operator training
Premium Annual preventative maintenance contract guaranteed parts availability within hours priority technical support
Platinum Full operational maintenance contract fixed cost per operating hour covering all parts labor consumables excluding wear liners

Options de financement:
Equipment leasing structures operating leases project financing through partner institutions milestonebased progress payments

FAQ

What are the lead times typically involved?
From order confirmation delivery ranges between weeks depending on final configuration complexity Factory acceptance testing FAT can be arranged prior shipment

How does this integrate with our existing screening or conveying equipment?
Our engineering team can conduct an audit Your existing equipment can often be incorporated into new plant design provided it meets capacity structural requirements avoiding unnecessary capital expenditure

What level operator training is provided?
Comprehensive training covers daily startup/shutdown procedures routine maintenance troubleshooting basic adjustments Training conducted both during commissioning ongoing basis as needed

Are wear parts readily available given it's white label?
Yes All critical wear parts jaw plates cone mantles screen media are manufactured standard dimensions held regional distribution centers ensuring availability comparable major OEM brands

What guarantees are provided on throughput capacity?
Plant performance guarantee provided based mutually agreed upon feed material characteristics sample testing Final performance validation conducted during commissioning using calibrated weighing equipment