1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, the reliability of crushing and screening equipment directly dictates profitability. Common challenges include:
Unscheduled Downtime: Component failures in critical crushers or screens halt entire production lines, costing thousands per hour in lost output and labor.
High Maintenance Costs: Frequent bearing changes, liner replacements, and vibration issues lead to excessive parts inventories and skilled labor overhead.
Inconsistent Product Quality: Inefficient screening and improper crushing chamber dynamics yield offspec aggregate, reducing saleable product volume.
Rising Energy Consumption: Older, inefficient drive systems and poorly optimized material flow place an unsustainable burden on your power costs.
Rigid Configuration Limitations: Fixed plant layouts struggle to adapt to changing feed materials or final product specifications, limiting operational flexibility.

Is your current equipment portfolio a source of constant cost management rather than a reliable foundation for growth? The solution lies in specifying machinery engineered to address these exact operational and financial pressures.

2. PRODUCT OVERVIEW

This product line encompasses a comprehensive range of highperformance stationary and mobile crushing and screening plants available for private label manufacturing. Engineered for primary, secondary, tertiary, and quaternary reduction stages, this equipment processes quarry rock, recycled concrete, asphalt, and industrial minerals.

Operational Workflow:
1. Primary Feeding & Crushing: Scalpers or grizzly feeders regulate material flow into robust jaw or primary impact crushers for initial size reduction.
2. Material Conveying: Highcapacity belt conveyors with impactresistant idlers transport crushed material to subsequent stages with minimal spillage and wear.
3. Secondary/Tertiary Crushing & Screening: Cone crushers or further impactors provide precise reduction. Integrated screens classify material, routing sized product to stockpiles and oversize back for further processing.
4. Final Product Stockpiling: Radial stackers or fixed conveyors create precisely blended stockpiles of finished aggregates.

Application Scope: Ideal for largescale aggregate production, mining prebeneficiation, construction & demolition recycling, and road base preparation.
Limitations: Not designed for ultrafine grinding (sub5mm) requiring specialized mills or for processing highly abrasive materials without specific liner alloy configurations.

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Optimized kinematics & cavity profile | Operational Benefit: Increases throughput by 1015% while maintaining consistent product gradation and reducing crusher bottlenecking. | ROI Impact: Higher tonsperhour output directly lowers costperton metric.

Centralized Greasing System | Technical Basis: Automated, programmable lubrication to all major bearing points from a single station. | Operational Benefit: Eliminates manual greasing errors, extends bearing service life by up to 40%, and improves site safety. | ROI Impact: Reduces lubrication labor hours by 70% and prevents costly premature bearing failures.

Modular Screen Media System | Technical Basis: Quicktensioning wedge system for panel changeout. | Operational Benefit: Screen deck media can be replaced by two personnel in under one hour versus a halfday shift. | Operational Benefit: Minimizes downtime during product changeovers or maintenance events.

Hybrid Power Unit Option | Technical Basis: Dieselelectric drive system with power management software. | Operational Benefit: Enables peakload sharing, reduces fuel consumption by up to 25% in variable load conditions compared to standard dieselhydraulic systems. | ROI Impact: Significant reduction in operating fuel costs over the equipment lifecycle.

HeavyDuty Fabricated Frame | Technical Basis: Finite Element Analysis (FEA) designed steel construction with continuous welds at stress points. | Operational Benefit: Provides exceptional structural integrity under dynamic loads, resisting fatigue cracks that lead to major frame repairs.| ROI Impact: Extends structural life of plant chassis beyond industry average, protecting capital asset value.

Advanced PLC Control System | Technical Basis: Industrial programmable logic controller with humanmachine interface (HMI) for process monitoring.| Operational Benefit: Operators can adjust settings, track production data, and diagnose faults from a central location.| ROI Impact: Enables datadriven decision making to optimize efficiency and simplifies troubleshooting.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Crushing & Screening Solution | Advantage (% improvement) |
| : | : | : | : |
| Crusher Liner Life (Abrasive Rock) | ~450500 hours Manganese Steel| ~600650 hours with proprietary alloy blend| +25% increased wear life |
| Screen Deck ChangeOut Time| 46 hours (23 personnel)| <1 hour (2 personnel)| ~80% reduction in downtime |
| Average Energy Consumption (per ton processed)| Baseline (100%)| Optimized drives & chamber design| Up to 15% reduction |
| Plant ReLocation & Setup Time (Mobile Units)| 812 hour typical range| 46 hours with hydraulic assists & prerouted cabling| ~50% faster deployment |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 TPH to over 800 TPH for complete plant systems.
Power Requirements: Primary crusher drives from 75 kW to 400 kW; total plant connected load varies by configuration; available for global voltage standards (50/60Hz).
Material Specifications: Highstrength steel frames (S355J2); AR400 abrasionresistant steel at wear points; Premiumgrade bearings; Optional chromewhite iron or composite liners.
Physical Dimensions (Mobile Jaw Unit Example): Working length ~15m; Height ~4m; Width ~3m; Transport weight approx. 45 tonnes (varies).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; Dust suppression system compliant; Noise emissions designed to meet <85 dB(A) at operator stations.

6. APPLICATION SCENARIOS

Aggregate Producer – Hard Granite Quarry

Challenge: A Southeast US quarry faced excessive cone crusher mantle/bowl liner wear (~400hr life) causing high parts costs and unpredictable stoppages during peak demand.
Solution: Implementation of a tertiary crushing station featuring our cone crusher with patented chamber geometry and optional ultraabrasion resistant liner package.
Results: Liner service life extended to over 600 hours—a documented 50% increase—reducing annual liner costs by approximately $85,000 USD and stabilizing the production schedule.

C&D Recycling Contractor – Urban Redevelopment

Challenge: A contractor needed rapid sitetosite mobility between projects while processing reinforced concrete with high rebar content without constant jams.
Solution: Deployment of a trackmounted mobile impact crushing plant equipped with an overband magnet system reinforced hydraulic drive protection against uncrushables.
Results: Plant relocation time reduced to under five hours per move. The system’s design eliminated catastrophic downtime from rebar entanglement increasing overall availability by an estimated 30%, allowing completion of two additional projects within the annual schedule.

Mining PreBeneficiation – Iron Ore

Challenge: A processing facility required consistent 40mm feed from lump ore but experienced frequent screen blinding due to high moisture content in seasonal periods.
Solution: Integration of our highfrequency linear vibrating screen deck featuring the modular tensioning system nonblinding polyurethane panels
Results: Screen availability increased from 95%. The quickpanel change system allowed rapid adaptation panel types based seasonal feed conditions minimizing process upsets

Commercial Considerations

Equipment is offered through tiered pricing aligned with configuration complexity:

Tier I – Base Mobile Unit Standard features single crushing stage basic screening
Tier II – Pro Configuration Includes hybrid power option advanced automation secondary crushing circuit
Tier III – Custom Plant Fully engineered stationary semistationary solution tailored specific material flow capacity requirements

Optional Features Hydraulic adjustment systems dust encapsulation packages winterization kits remote monitoring telemetry

Service Packages Available:
1) Basic Warranty – Standard parts labor coverage months
2) Extended Protection Plan – Comprehensive coverage up months including wear components
3) Full Service Agreement – Scheduled maintenance inspections priority parts dispatch guaranteed response times

Financing Options Flexible commercial leasing capital equipment loans operating lease structures available through partnered financial institutions facilitating cash flow management

FAQ

What level customization available private label program?
We offer extensive customization from component branding full engineering collaboration develop unique model designations meet your specific market requirements technical specifications

How does equipment integrate existing plant infrastructure?
Our engineering team provides interface drawings specifications ensure compatibility existing conveyors feeders electrical supply Control systems designed communicate via standard industrial protocols Modbus OPC UA)

What typical lead time commissioning after order placement?
Lead times vary configuration complexity For standard mobile units delivery typically within weeks Custom stationary plants require detailed engineering project timeline provided upon scope finalization Commissioning supervised our technicians included purchase

What key operator training maintenance support provided?
Comprehensive training conducted onsite covering safe operation routine maintenance troubleshooting procedures Detailed manuals schematics provided digitally Ongoing technical support available via dedicated hotline

Are performance guarantees offered?
Yes we provide guaranteed minimum throughput capacity product gradation curves based agreed feed material characteristics These are validated during factory acceptance testing commissioning

What are payment terms minimum order quantities?
Standard terms require deposit order confirmation balance prior shipment MOQs apply private label program discussed confidentiality agreement