1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your plant's profitability? In industrial crushing and screening, key challenges directly impact your bottom line. High wear part consumption leads to frequent, costly shutdowns for liner changes and component replacement. Inconsistent feed material causes chokeups or bridging, stalling production and creating safety hazards. Inefficient particle size distribution results in excess recirculating load, wasting energy and reducing final product yield. Furthermore, inadequate screening performance allows undersize material to bypass the circuit or oversize to carry over, compromising product specs and leading to customer rejections.

How can you achieve higher throughput with lower energy consumption per ton? What solutions exist to extend maintenance intervals and standardize wear parts? Is it possible to improve product consistency while adapting to variable feed stock? The answer lies in selecting engineered industrial crushing and screening equipment designed for total cost of ownership.

2. PRODUCT OVERVIEW

This product line encompasses heavyduty primary, secondary, and tertiary crushers paired with multideck vibrating screens for fixed or mobile hard rock processing plants. The operational workflow is a closedcircuit system: (1) Raw feed is introduced into the primary crusher for initial size reduction. (2) Crushed material is conveyed to a primary screen for separation. (3) Oversize material is routed to secondary/tertiary crushers. (4) Correctly sized material from all screening stages is sent to product stockpiles, while crusher discharge is recirculated back to the screens. This equipment is engineered for processing abrasive aggregates, ores, and industrial minerals but has limitations with highly plastic, sticky materials without specialized configurations.

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Computermodeled kinematics and optimized nip angles | Operational Benefit: Maximizes interparticle crushing, reduces slabby output, and ensures even wear distribution across liners | ROI Impact: Up to 15% higher throughput at same power draw and 20% longer liner life documented in field data.

Modular Wear Part System | Technical Basis: Standardized, reversible manganese steel castings with multiple wearing surfaces | Operational Benefit: Reduces part inventory complexity, allows for faster infield rotation/replacement by maintenance crews | ROI Impact: Cuts wear part inventory costs by 30% and reduces planned changeout downtime by 40%.

DirectDrive Crusher & Screen Technology | Technical Basis: Elimination of Vbelts, sheaves, and complex gearboxes via integrated motor systems | Operational Benefit: Provides constant torque transfer with >95% drive efficiency, reduces maintenance points, and allows precise speed control | ROI Impact: Typical energy savings of 812% versus traditional indirect drives.

Independent MultiAxis Screen Vibration | Technical Basis: Separate vibrators on each screen deck allowing adjustable amplitude/frequency per deck | Operational Benefit: Operators can tailor screening action for each layer—scalping top deck, precision sizing lower decks—within a single machine | ROI Impact: Improves screening efficiency by up to 15%, reducing crusher recirculation load and boosting final product yield.

Centralized Greasing & Condition Monitoring Ports | Technical Basis: Automated lubrication system with feed lines to all major bearings and accessible sensor ports | Operational Benefit: Ensures critical components receive correct lubrication without manual intervention; enables easy connection of vibration/temperature sensors | ROI Impact: Prevents ~90% of bearing failurerelated downtime; enables predictive maintenance planning.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Crushing & Screening Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tons per Hour per kW (TPH/kW) | 810 TPH/kW (for midrange abrasives) | 1113 TPH/kW (for midrange abrasives) | +25% Efficiency |
| Wear Part Cost per Ton ($/ton) | $0.45 $0.65 /ton processed (avg.)| $0.32 $0.48 /ton processed (field verified)| 28% Cost/Ton |
| Screening Accuracy (Efficiency) @ 10mm cut point| 8588% typical efficiency| Consistently >92% efficiency| +57 Points |
| Mean Time Between Failure (MTBF) Major Components| ~1,200 hours| >1,800 hours documented average| +50% Uptime |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Primary Jaw Crushers from 500 1,800 MTPH; Cone Crushers from 200 900 MTPH; MultiDeck Screens from 300 1,500 TPH capacity.
Power Requirements: Plant configurations from 400 kW to 1.5 MW total connected load; compatible with Tier IV Final / Stage V diesel gensets or grid connection; voltage requirements from 480V to 6kV.
Material Specifications: Fabricated main frames from hightensile steel plate (min. yield strength 350 MPa); crusher liners in premium manganese steel (1822%); screen decks available in polyurethane, rubber, or woven wire.
Physical Dimensions: Configurations designed for transport under standard road regulations; largest single unit transport weight under 45 metric tons.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +50°C; dustsealed bearings; weatherprotected electricals standard.

6. APPLICATION SCENARIOS

Granite Aggregate Quarrying & Base Material Production

Challenge: A large quarry faced high recirculating loads (>40%) due to poor cubicity from its secondary crusher and screen blinding on damp days, capping plant output at 550 TPH against a design goal of 650 TPH.
Solution: Implementation of a highinertia cone crusher with a patented chamber design paired with two multiaxis screens featuring nonblinding polyurethane decks.
Results: Achieved sustained throughput of 680 TPH with recirculating load reduced to <25%. Product cubicity improved by 22%, meeting premium road base specifications.

Iron Ore Processing – Secondary Crushing Circuit

Challenge: An iron ore plant experienced excessive unplanned downtime due to premature bearing failures in its vibrating screens handling heavy loads of abrasive material.
Solution: Retrofit installation of new heavyduty screens featuring centralized automated greasing systems on all bearings and directdrive vibrators.
Results: Bearingrelated failures were eliminated over an 18month tracking period. Availability of the screening circuit increased from 88% to >96%, contributing an estimated additional 85k tons of annual production.

7. COMMERCIAL CONSIDERATIONS

Industrial crushing and screening equipment pricing is tiered based on capacity scale:
Tier A – HighCapacity Stationary Plants (>1000 TPH): Capital investment reflects custom engineering for maximum uptime at scale.
Tier B – MidRange Modular Plants (3001000 TPH): Balanced offering featuring preengineered modules optimized for fast deployment.
Tier C – Compact & Mobile Units (<300 TPH): Focus on flexibility for contract crushing or satellite sites.

Optional features include advanced automation packages (PLC control with remote monitoring), dust suppression systems certified for specific regions ,and specialized wear liners for ultraabrasive applications . Comprehensive service packages are available ,from basic commissioning support up through fullsite operationandmaintenance contracts . Financing options include capital leases ,operating leases ,and projectbased rentaltoown structures tailored for capital expenditure planning .

8.FAQ

Q1:What level of preparation is required at my site before installation?
A1:A stable ,level concrete foundation designed by a qualified structural engineer based on our supplied load data is mandatory .Properly sized feed hoppers ,conveyors ,and electrical supply infrastructure must be in place prior to commissioning .

Q2:What training do you provide for our operations team?
A2 We provide comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting guides specific technical documentation This ensures your team achieves target performance levels quickly

Q3:What are typical lead times after order placement?
A3 Lead times vary by configuration complexity For standard modular plants lead time typically ranges between weeks Custom engineered high capacity solutions may require months Detailed project schedules are provided upon application review

Q4 How does this equipment handle variations in feed material hardness or moisture content?
A4 The hydraulic adjustment systems on our crushers allow operators compensate real time changes hardness maintain consistent product size Screen decks can specified various materials combat blinding caused moisture while adjustable vibration parameters help maintain efficiency

Q5 What warranty coverage offered?
A5 We offer month warranty defects materials workmanship Wear parts consumables like liners screen media covered separate wear life warranty based guaranteed minimum tonnage processed