1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are your aggregate production targets consistently undermined by equipment mismatch? Standard, offtheshelf crushing and screening plants often force operational compromises, leading to tangible losses. Considérez ces défis communs:
Underperformance: A plant sized for limestone struggles with abrasive granite, causing premature wear, temps d'arrêt imprévu, et un 1525% drop in throughput.
Rigidité: Les exigences du marché évoluent, but your fixedconfiguration line cannot efficiently produce a new spec product without costly, timeconsuming modifications.
Coûts opérationnels élevés: Inefficient layout and nonoptimized component interaction increase fuel/power consumption per ton and elevate maintenance labor hours.
Contraintes d'empreinte: Available site space is limited, preventing the deployment of a standard modular setup that meets your required capacity.
Problèmes d'intégration: Adding new equipment to an existing flow creates bottlenecks, transfer point issues, and control system conflicts.

What if your plant was engineered from the ground up to address your specific material, site, and output goals? This is the fundamental question driving the need for customized solutions.

2. APERÇU DU PRODUIT: CUSTOMIZED CRUSHING AND SCREENING SOLUTIONS

A Customized Crushing and Screening Plant is a purposeengineered system where primary, secondaire, et concasseurs tertiaires, écrans, convoyeurs, and control systems are selected and integrated as a cohesive unit. The workflow is tailored but follows a key optimized sequence: (1) Primary size reduction matched to feed material hardness and size; (2) Strategic prescreening to remove fines or scalp oversize; (3) Closedcircuit secondary/tertiary crushing for precise product shaping; (4) Final screening into multiple product fractions; (5) Centralized logic control for coordinated operation. These systems are designed for operations with specific longterm requirements where volume, caractéristiques des matériaux, or space preclude standard models. They are not typically suited for shortterm projects requiring rapid deployment without capital commitment.

3. CARACTÉRISTIQUES PRINCIPALES

Engineered Flow Design | Base technique: Dynamic process simulation software | Avantage opérationnel: Eliminates bottlenecks and ensures all components operate at peak synergistic efficiency | Impact sur le retour sur investissement: Achieves rated plant capacity consistently, maximizing asset utilization and revenue potential.

Component Synergy Selection | Base technique: Proprietary compatibility matrices based on duty cycle analysis | Avantage opérationnel: Crusher chambers, types de supports d'écran, and conveyor speeds are matched to prevent overloading or underutilization | Impact sur le retour sur investissement: Réduit la consommation d’énergie spécifique (kWh/tonne) jusqu'à 18% versus mismatched assemblies.

Structural Optimization | Base technique: Analyse par éléments finis (FEA) sur les structures porteuses | Avantage opérationnel: Delivers robust support with minimized weight and adaptable footprint for challenging sites | Impact sur le retour sur investissement: Lowers foundation costs and expands viable installation locations without structural compromise.

Proactive Maintenance Architecture | Base technique: Strategically placed smart sensor points and accessible service platforms | Avantage opérationnel: Enables conditionbased monitoring and reduces service time for liner changes, belt maintenance, and bearing inspections | Impact sur le retour sur investissement: Cuts planned maintenance downtime by an average of 30% through improved access and predictability.

Scalable Control Integration | Base technique: Modular PLC/SCADA systems with standardized communication protocols | Avantage opérationnel: Provides singlepoint operational control with easy future expansion capability for added circuits or peripherals | Impact sur le retour sur investissement: Protects initial automation investment and simplifies future upgrades.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Usine modulaire) | Customized Crushing Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Tons per Hour Consistency| +/ 12% from rated capacity due to suboptimal flow | +/ 5% from engineered design capacity| +7% Effective Utilization |
| Coût d'usure par tonne| Based on average material assumptions| Calculated & mitigated for your specific abrasion index & teneur en silice| Jusqu'à 22% Réduction |
| Déménagement & Temps de reconfiguration| 23 weeks for disassembly/reassembly| Streamlined due to purposedesigned modules & documentation| ~35% Faster Redeployment |
| Main d'œuvre d'installation sur site| High due to fitup adjustments & alignement| Minimized through factory preassembly & testing of subsystems| ~25% Fewer ManHours |

5. SPÉCIFICATIONS TECHNIQUES

Les spécifications sont déterminées par les exigences du projet. A typical midrange customized plant framework includes:

Plage de capacité: 200 à 800 tonnes par heure (TPH), engineered for specific material density (par ex., 1.6 t/m³ crushed granite).
Exigences d'alimentation: Integrated electrical system from 800 kVA à 2500 kVA; designed for grid or genset supply with softstart capabilities.
Spécifications matérielles: Wear liners in primary zones specified as Mn18Cr2 or higher; chute work in AR400 steel; dust suppression spray points at all transfer stations.
Dimensions physiques: Layout engineered to client’s spatial constraints; typical footprint range from 40m x 70m to 60m x 120m.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust emission controls designed to meet local particulate matter (PM10/PM2,5) règlements.

6. SCÉNARIOS D'APPLICATION

Agrandissement de la carrière de granit | Défi: A quarry needed to increase production of railway ballast and concrete aggregate simultaneously without expanding its permitted site boundary. Standard plants required too much space. Solution: Mise en œuvre d'un pacte, verticaldesign customized crushing circuit featuring a highreductionratio cone crusher in closed circuit with a multideck screen stacked over the feed conveyor. Résultats: Achieved target 600 TPH output within the existing footprint; produced precisely cubical ballast product meeting ASTM D448 specifications; reduced overall plant height by 25%, simplifying dust enclosure.

Urban Recycling Operation | Défi: Processing construction & demolition waste with highly variable composition led to frequent jamming in standard impactors and excessive wear from hidden rebar. Solution: A customized heavyduty crushing circuit centered on a slowspeed, hightorque sheartype primary crusher followed by an overhead crossbelt magnet and an aggressive prescalping screen. Résultats: Throughput of mixed C&D waste stabilized at 220 TPH; reduced unplanned stoppages by over 60%; extended wear part life on primary unit by approximately 40%.

7. CONSIDÉRATIONS COMMERCIALES

Customized crushing solutions are capital investments structured around project scope:

Niveaux de tarification: Based on system complexity—(1) Basic Customization (component selection/layout), (2) Full Circuit Design & Construire (greenfield systems), (3) Legacy System Retrofit & Intégration.
Fonctionnalités facultatives: Advanced automated level sensing, remote telematics packages for performance tracking, supplemental noise abatement enclosures,
spare part kits aligned with predicted wear schedules.
Forfaits de services: Typically include firstyear comprehensive warranty + optional extended coverage plans covering parts/labor or inspectionbased maintenance contracts.
Options de financement: Project financing available through partner institutions covering equipment leasing/purchase agreements tailored around project startup timelines.

8. FAQ

1. How do you ensure the customized plant design will perform as modeled? We employ industrystandard process simulation software validated against decades of field data from thousands of installations. Key performance guarantees are established during the engineering phase based on your provided material samples.
2. What is the typical lead time from design approval to commissioning? For a full custom circuit designbuild project using established componentry like our own cone crushers or screens lead times typically range between eight months depending on final specifications
3.
4.Can we integrate existing equipment we own into the new custom flow? Yes integration feasibility studies are part of our initial assessment We evaluate compatibility control integration potential
5.What does aftersales support look like compared
6.Are there financing structures that align payments with projected production increases from the new plant?
7.How do you handle ongoing technical support