1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing the escalating costs and logistical complexities of sourcing sand and gravel? Relying on inconsistent thirdparty suppliers directly impacts your project timelines, budget control, and final product quality. Les défis courants incluent:

Unpredictable Supply & Cost Volatility: Market fluctuations and transportation bottlenecks lead to budget overruns and project delays.
Inconsistent Material Specification: Variations in grain size, composition, and cleanliness from external suppliers compromise the integrity of your concrete or asphalt mixes.
Lack of Operational Control: Dependence on external parties limits your ability to adjust to projectspecific demands or urgent schedule changes.
Hidden Logistics & Quality Costs: Expenses related to quality testing, rejection handling, and lastminute sourcing erode your profit margins.

What if you could transition from a reactive purchaser to a strategic producer? How would direct control over your aggregate supply chain affect your operational resilience and bottom line?

2. APERÇU DU PRODUIT: MOBILE TRACKMOUNTED CRUSHING AND SCREENING PLANTS

A mobile trackmounted crushing and screening plant is a selfcontained processing system that enables insitu production of sand and gravel. It transforms raw feed material (par ex., bank run, oversize rock, river deposits) into precisely graded commercial aggregates at the extraction site.

Flux de travail opérationnel:
1. Alimentation & Concassage primaire: Raw material is loaded into a vibrating feeder, conveying it to a jaw or impact crusher for initial size reduction.
2. Traitement secondaire & Dépistage: Crushed material is conveyed to a secondary cone crusher for further refinement, then fed onto multideck vibrating screens.
3. Product Sorting & Stockage: Screens separate material into designated product sizes (par ex., coarse gravel, fine sand). Conveyors transfer sorted aggregates to individual stockpiles for immediate use or transport.

Champ d'application: Ideal for establishing temporary or permanent pits, processing demolition concrete for recycled aggregate, and developing satellite quarries near large construction projects.

Principales limites: Requires suitable feed material meeting geological criteria; not a substitute for a highvolume stationary plant for megascale, multidecade quarry operations.

3. CARACTÉRISTIQUES PRINCIPALES

Direct Feed System | Base technique: Integrated vibrating grizzly feeder with bypass chute | Avantage opérationnel: Removes natural fines and undersize material before primary crushing, reducing crusher wear and increasing effective capacity | Impact sur le retour sur investissement: Lowers wear part costs by up to 18% and improves total throughput

Hybrid DieselElectric Drive | Base technique: Diesel generator powers full electric crusher and conveyor motors | Avantage opérationnel: Significant fuel savings versus purely hydraulic drives, with precise motor control for consistent product grading | Impact sur le retour sur investissement: Les données de terrain montrent 2230% reduction in fuel consumption per ton of material processed

Advanced Process Automation | Base technique: PLCbased control system with touchscreen interface | Avantage opérationnel: Your operators can monitor performance, ajuster les paramètres, and diagnose issues from a central location | Impact sur le retour sur investissement: Reduces unplanned downtime by facilitating proactive maintenance; improves yield consistency

Configuration rapide & Déménagement | Base technique: Hydraulic folding conveyors, track mobility, and integrated jacking system | Avantage opérationnel: Plant can be operational within hours of arrival on site and easily moved between pits | Impact sur le retour sur investissement: Maximizes equipment utilization across multiple projects; eliminates costly permanent foundations

MultiLayer Precision Screening | Base technique: Highfrequency vibrating screens with adjustable throw and tensioning | Avantage opérationnel: Produces up to four calibrated aggregate products simultaneously with minimal blinding | Impact sur le retour sur investissement: Increases saleable product yield from each ton of feed; meets strict ASTM/EN specifications

HeavyDuty Component Access | Base technique: Hydraulically folding service platforms and wide crusher doors | Avantage opérationnel: Permet de sécuriser, rapid maintenance and wear part replacement for mechanics | Impact sur le retour sur investissement: Cuts scheduled service time by approximately 40%, increasing annual operating hours

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Usine mobile) | Mobile TrackMounted Solution | Avantage (% amélioration) |
| : | : | : | : |
| Fuel Consumption per Ton Processed| 0.8 1.1 liters/tonne| 0.6 0.7 liters/tonne| ~25% improvement |
| Average Setup / Temps de démontage| 23 jours ouvrables| < 8 heures| ~80% faster relocation |
| Crusher Wear Life (Matériau abrasif)| ~450 operating hours| ~550 operating hours| ~22% longer service life |
| Product Yield (InSpec Material)| ~8588% of feed mass| ~9093% of feed mass| ~5% increase in saleable product |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèles disponibles chez 150 à 400 tonnes per hour final product output.
Power Plant: Étage 4 Final / Stage V compliant diesel generator sets from 250 kVA à 500 kVA.
Options du concasseur primaire: Corbeau à mâchoires (feed size up to 650mm) or horizontal shaft impactor (for softer rock/recycling).
Concasseur secondaire: Cone crusher with hydraulic setting adjustment for precise product shaping.
Main Screen: Heavyduty tripledeck vibrating screen (1620 sqm screening area).
Track Mobility: Hydraulic track drive system with remote control movement capability.
Operating Dimensions (LxlxH): Approximately 28m x 3m x 4m (transport mode); expands during operation.
Plage de fonctionnement environnementale: Designed for 20°C to +45°C ambient temperatures; dust suppression system standard.

6. SCÉNARIOS D'APPLICATION

Regional Construction Contractor & Aggregate Supplier

Défi: Needed consistent supply of DOTspec aggregates for highway projects across a wide region; thirdparty supplier costs became prohibitive.
Solution: Deployed one mobile trackmounted plant to establish shortterm pits at two different project corridors.
Résultats: Achieved direct control over supply, reducing aggregate cost per ton by 35%. Produced over 120,000 tons of material across two seasons.

Sable & Gravel Pit Operator Expanding Product Line

Défi: Existing stationary plant could not efficiently produce manufactured sand (poussière de concasseur) required for concrete mix customers.
Solution: Integrated a mobile crushing/screening plant with a dedicated sand classification module as a supplementary processing line.
Résultats: Added two new highvalue spec sand products to their portfolio without major capital investment in the fixed plant. Increased overall site revenue by an estimated 18%.

Démolition & Recycling Specialist

Défi: Needed to process reinforced concrete demolition waste into clean RCA (Granulat de béton recyclé) at various urban sites with space constraints.
Solution: Utilized a mobile jaw/impactor/screen combination plant equipped with an overband magnet.
Résultats: Processed over 65,000 tons of rubble onsite annually, creating saleable RCA while eliminating landfill tipping fees—transforming a cost center into a profit center.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification:
Configuration de base (HighProduction Gravel): Focused on highvolume production of coarse aggregates.
Premium Configuration (Washed Sand & Gravier): Includes integrated cyclones or screw classifiers for washed spec sand production.
Recycling Configuration: Enhanced with stronger magnets, air separators, and impact crushers optimized for concrete/asphalt recycling.

Fonctionnalités facultatives: Remote telematics monitoring package; additional stacking conveyors; hybrid power connection capability; advanced water recycling systems.

Forfaits de services: Choose from scheduled maintenance plans offering guaranteed parts availability/labor rates or comprehensive fullservice contracts covering all wear parts except liners.

Options de financement: Solutions include equipment leasing/purchase plans tailored to cash flow cycles typical in bulk materials production.

FAQ

1. What type of raw feed material is required?
The plant requires competent feed material that can be excavated without blasting (par ex., bank run gravels). A preliminary geotechnical assessment is recommended to confirm suitability.

2. How does this solution impact our existing logistics?
It fundamentally shifts logistics from transporting heavy finished aggregates over long distances to moving only the processing plant periodically between source locations closer to enduse sites.

3. What are the primary operational cost drivers?
The main variables are fuel consumption based on material hardness/density; wear part replacement cycles dependent on abrasiveness; screen media life based on wire tensioning practices.

4. What technical support is available during commissioning?
Commissioning includes comprehensive operator training conducted at your site by factorycertified technicians covering daily operation routine maintenance procedures troubleshooting protocols safety systems functionality checks startup/shutdown sequences performance optimization techniques best practices documentation review handover signoff process completion criteria verification postcommissioning followup schedule establishment remote support access setup reporting requirements clarification warranty terms explanation spare parts ordering procedure demonstration record keeping recommendations final report issuance debrief meeting scheduling future service plan discussion optional upgrades presentation feedback collection continuous improvement suggestions documentation archiving knowledge transfer confirmation competency assessment optional certification issuance process completion acknowledgment next steps planning longterm partnership framework establishment mutual success metric 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