1. PAINPOINT DRIVEN OPENING

Are you managing a stone quarry operation where inconsistent feed, unplanned downtime, and rising operational costs are eroding your margins? Key challenges in primary crushing include:

Excessive Downtime for Maintenance: Frequent liner changes and unexpected component failures in the primary crusher can halt your entire processing line for hours, costing thousands in lost production per event.
High Wear Part Costs: Abrasive feed material leads to rapid wear of crusher jaws, mantles, and concaves, creating a significant and recurring expense for your parts inventory.
Inconsistent Throughput & Product Gradation: Fluctuations in feed size or hardness can cause chokefeeding or poor cavity utilization, resulting in suboptimal tonnage and offspec product that requires recrushing.
Energy Inefficiency: Older or poorly configured crushing plants consume excessive power per ton of processed material, directly impacting your bottom line as energy costs rise.
Structural Integrity Concerns: The immense forces generated in a primary crushing station demand a fabricated structure of exceptional durability. Inadequate design can lead to costly frame fatigue, cracks, and alignment issues over time.

How do you select a crushing plant fabricator that not only provides robust equipment but also delivers the operational reliability and total cost of ownership metrics that your business requires?

2. PRODUCT OVERVIEW: ISOCertified Stationary Primary Crushing Plant

We engineer and fabricate heavyduty, stationary primary crushing plants designed as the cornerstone of hard rock quarry operations. These turnkey solutions are built to receive blasted feed from haul trucks and reduce it to a consistent, conveyable product for secondary processing.

Operational Workflow:
1. Feed & PreScreening: Runofquarry (ROQ) material is dumped into a rugged vibrating grizzly feeder (VGF), which scalps out fine undersize material to bypass the crusher, improving efficiency.
2. Primary Size Reduction: Oversize material is directed into a highcapacity jaw crusher (or gyratory crusher, depending on application) where it is compressed and fractured against fixed and moving surfaces.
3. Product Conveyance: Crushed material is discharged onto a heavyduty main product conveyor, transporting it to the next stage of the processing circuit.

Application Scope: Ideal for hightonnage processing of granite, basalt, limestone, and other abrasive aggregates. Suited for permanent installation in largescale quarry operations.

Limitations: Not designed for portable or mobile applications. Maximum feed size is determined by crusher model selection; extremely sticky or claybound materials may require additional preprocessing.

3. CORE FEATURES

Modular Fabricated Base Frame | Technical Basis: CADoptimized, highstrength steel weldment with internal reinforcing diaphragms | Operational Benefit: Provides an unwavering foundation that maintains precise crusher and motor alignment under cyclical loading | ROI Impact: Eliminates costly realignment downtime and extends bearing & drive component life by up to 30%.
Integrated Maintenance Platforms & Access | Technical Basis: Ergonomic design per ISO safety standards with nonslip grating, guardrails, and strategic service points | Operational Benefit: Your crew can perform routine inspections, liner checks, and maintenance tasks safely and efficiently | ROI Impact: Reduces service time by an average of 25%, lowering labor costs and increasing plant availability.
HeavyDuty Vibrating Grizzly Feeder (VGF) Section | Technical Basis: Robust deck construction with replaceable grizzly bars and highinertia vibrator motors | Operational Benefit: Effectively removes fines while absorbing direct impact from haul truck dumping | ROI Impact: Increases primary crusher capacity by preventing chokefeeding with fines; protects crusher from shock loads.
Centralized Lube & Hydraulic System | Technical Basis: Manifolded system with failsafe indicators and easyaccess service ports | Operational Benefit: Enables safe, clean, and consistent lubrication of all critical crusher bearings from a single location | ROI Impact: Standardizes maintenance procedures prevents lubrication failures which are a leading cause of major component damage.
Cable Management & Utility Routing | Technical Basis: Prefabricated steel conduits and trays integrated into the plant structure | Operational Benefit: Protects power and control cables from damage dust contamination ensuring reliable electrical supply | ROI Impact: Minimizes electrical faults reduces installation time onsite by providing a plugandplay wiring infrastructure.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Practice | Our ISOCertified Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Structural Durability (Fatigue Life) | Fieldwelded fabrication with variable quality control; potential for stress points. | Plantwide FEA analysis; precision shopwelding under controlled conditions per ISO 38342. +40% estimated service life before major refurbishment. |
| OnSite Installation & Commissioning Time| 46 weeks for foundation work assembly alignment testing. Modular design with preassembled sections; laseraligned at factory. 50% onsite labor time reduced project risk. |
| Operational Availability (Uptime) ~92% based on typical maintenance schedules unplanned stops.| >95% documented via telemetry from installed units optimized access predictive maintenance design.| +3 percentage points translating to significant annual tonnage gains. |
| Energy Consumption per Ton Processed| Varies widely older drives directonline starting.| Engineered drive train efficiency softstart systems optimized kinematics.| Field data shows 815% reduction in specific energy consumption |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable for throughputs from 400 to 2 000+ metric tons per hour (TPH)
Primary Crusher Options: Jaw Crusher (900 x 1200mm to 1500 x 2000mm) or Primary Gyratory Crusher
Grizzly Feeder: Widths from 1 200mm to 2 400mm; lengths from 4 500mm to 7 500mm
Power Requirements: Total installed power typically between 250 kW 600 kW dependent on configuration
Material Specifications: Main frame fabricated from S355JR structural steel; wear surfaces utilize AR400 abrasionresistant steel liners
Physical Dimensions (Typical): Approximate footprint of 18m (L) x 8m (W) x 9m (H). Custom designs available
Environmental Operating Range Designed for ambient temperatures from 20°C to +45°C dust moisture conditions typical of outdoor quarry operation

6. APPLICATION SCENARIOS

Granite Quarry Expansion Southeast Asia Challenge A major quarry needed to double primary circuit capacity but had limited space for new foundations faced stringent noise/vibration regulations Solution A compact highcapacity jaw crusher plant was designed with an integrated acoustic enclosure vibrationisolation pads mounted on a single deeppile foundation Results Achieved target throughput of 1 200 TPH within existing site footprint community noise complaints reduced by 60%

Basalt Processing Plant Upgrade North America Challenge Chronic downtime due to frame fatigue cracks poor accessibility for mantle changes on an aging primary station Solution Complete replacement with a customfabricated primary plant featuring reinforced modular base walkin maintenance platforms around the crusher Results Mantle changeout time reduced from 36 hours to 14 hours no structural integrity issues reported after 3 years of continuous operation

7 COMMERCIAL CONSIDERATIONS

Our ISOcertified fabrication process ensures transparent costing predictable delivery schedules

Pricing Tiers
1 Base Plant Includes fabricated structure VGF crusher mounting main discharge conveyor walkways ladders
2 Premium Package Adds centralized automated lube system integrated dust suppression spray system premium motor starters
3 Turnkey Pro Includes full electrical control package PLC instrumentation advanced condition monitoring sensors

Optional Features Acoustic cladding special coatings for corrosive environments custom feed hopper designs belt scales metal detection

Service Packages Extended warranty plans scheduled inspection services remote performance monitoring subscriptions wear part supply agreements

Financing Options Available through partner institutions including equipment leasing longterm rental plans tradein options for existing assets

8 FAQ

What level of site preparation is required prior to delivery?
We provide detailed foundation drawings load data anchor bolt templates Your contractor prepares the civil works according to our specifications ensuring our team can commence efficient mechanical erection

How does your fabrication quality control impact longterm reliability?
Our ISO 9001 38342 certifications mandate documented procedures for material traceability welding qualifications dimensional checks This systematic approach eliminates defects that cause premature failure ensuring predictable lifecycle costs

Can this plant be integrated with my existing secondary circuit conveyor?
Yes Our design team will engineer the discharge height conveyor speed transfer point to match your existing system specifications We ensure seamless material flow integration

What is the typical lead time from order placement to commissioning?
Lead times vary based on project scope complexity A standard configured plant typically has a 68 month timeline including engineering procurement fabrication testing disassembly shipping Site commissioning requires approximately 34 weeks with our supervision

Do you provide operational training for our crew?
Yes Comprehensive training covering safe operation routine maintenance procedures basic troubleshooting is provided during commissioning Documentation includes detailed operation maintenance manuals