1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and contractors, the crushing and screening circuit is often the bottleneck where profit is won or lost. Common challenges include:
Unscheduled Downtime: Component failures in critical crushers or screeners halt entire production lines, costing thousands per hour in lost output and labor.
High Maintenance Costs: Frequent wear part replacement and extensive manual adjustments consume both budget and skilled technician hours.
Inconsistent Product Quality: Inefficient screening and improper crushing lead to offspec aggregate, resulting in product rejection, reprocessing costs, and damaged client relationships.
Energy Inefficiency: Older, nonoptimized equipment consumes excessive power per ton of material processed, directly impacting your bottom line.
Rigid Configuration: Fixed plants cannot adapt to changing feed material or final product requirements, limiting operational flexibility and contract opportunities.

What if your primary crushing station and screening deck could deliver not just throughput, but predictable performance, lower costperton, and the agility to meet shifting market demands?

2. PRODUCT OVERVIEW

This product line encompasses a range of premium stationary and semistationary crushing and screening plants engineered for highvolume aggregate production, mining precrushing, and construction & demolition recycling. The operational workflow is designed for continuous, efficient material processing:

1. Primary Feeding & Crushing: Dump trucks feed material into a rugged vibrating grizzly feeder which removes fines and directs oversize to a highcapacity jaw or gyratory crusher for initial size reduction.
2. Intermediate Conveying & Crushing: Crushed material is conveyed to secondary cone or impact crushers for further refinement, with metal detectors and tramp iron relief systems protecting downstream components.
3. PreScreening & Classification: Material may be routed through a scalping screen before secondary crushing to improve efficiency.
4. Final Screening & Stockpiling: The crushed aggregate is classified into precise specifications by multideck vibrating screens, with conveyors directing sorted material to designated stockpiles.

Application Scope: Ideal for largescale quarrying, hard rock mining primary circuits, and major infrastructure projects requiring consistent, highquality aggregates (040mm+). Limitations include suitability primarily for fixed or semifixed installation sites; highly mobile contract crushing requires dedicated portable equipment.

3. CORE FEATURES

Hydroset CSS Adjustment | Technical Basis: Hydraulic piston supporting the main shaft | Operational Benefit: Closedside setting (CSS) can be adjusted safely in under 60 seconds without stopping the crusher, enabling rapid response to product gradation changes. | ROI Impact: Eliminates hours of manual shim adjustment downtime per change, increasing plant utilization by up to 7% annually.

Modular Screen Media System | Technical Basis: Interlocking polyurethane or rubber panels with tensioning rails | Operational Benefit: Panels can be replaced by a twoperson crew in under 30 minutes per deck without specialized tools. | ROI Impact: Reduces screen deck maintenance downtime by over 50% compared to traditional woven wire cloth systems.

PLCBased Plant Automation | Technical Basis: Centralized programmable logic controller with touchscreen HMI | Operational Benefit: Monitors amp draw, bearing temperatures, and feed rates; automatically regulates feeder speed and triggers alarms for preventative intervention. | ROI Impact: Prevents catastrophic failures; field data shows a typical 1520% reduction in unplanned stoppages.

Direct Drive Crusher Technology | Technical Basis: Crusher coupled directly to motor via Vbelts without gearboxes | Operational Benefit: Higher power transmission efficiency (over 95%) and reduced mechanical complexity. | ROI Impact: Lowers energy consumption by up to 10% versus indirect drives and reduces potential failure points.

Tier 4 Final / EU Stage V Power Unit Integration | Technical Basis: Factoryintegrated, emissionscompliant diesel gensets or electric motor drives with soft starters | Operational Benefit: Provides compliant power flexibility for remote sites or grids with limited capacity; soft starters reduce electrical network stress. | ROI Impact: Simplifies permitting; reduces peak current demand charges on electric installations.

Reinforced BoxSection Conveyor Frames | Technical Basis: Highstrength welded steel construction with internal stiffeners | Operational Benefit: Withstands continuous heavyimpact loading without frame deflection or misalignment. | ROI Impact: Extends conveyor belt life by maintaining proper tracking; reduces structural maintenance over the plant's lifetime.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Crushing & Screening Solution Documented Advantage |
| : | : | : |
| Tons per Hour (TPH) Availability | 8588% availability over a quarter >90% availability over a quarter +35% improvement |
| CostPerTon (Wear Parts) USD $0.45 $0.55/ton processed USD $0.38 $0.42/ton processed Up to 20% reduction |
| Energy Consumption (kWh/ton) ~0.85 1.1 kWh/ton ~0.75 0.95 kWh/ton Up to 15% improvement |
| Screen Media Change Time (per deck) ~90 120 minutes <30 minutes Over 60% faster |
| CSS Adjustment Time (Cone Crusher) ~60 90 minutes <2 minutes Over 95% faster |

_Availability defined as (Scheduled Operating Time Unscheduled Downtime) / Scheduled Operating Time._

5.TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 400 TPH to over 1,500 TPH final product output.
Primary Crusher Options: Jaw Crushers (1,200mm x 830mm feed opening) or Primary Gyratory Crushers (54” model).
Secondary/Tertiary Crushers: Heavyduty cone crushers with multiple chamber options.
Screening Units: Highenergy tripledeck vibrating screens (up to 8m² screening area per deck).
Power Requirements: Full plant electric configuration typically requires a mains supply of 800kVA – 2MVA; integrated diesel genset options available.
Key Material Specifications: Manganese steel crusher jaws/liners (18% Mn); Hardox® liners in hoppers and chutes; SKF/FAG class bearings throughout.
Physical Dimensions (Typical Plant Footprint): Approximately L70m x W25m x H15m (varies significantly with configuration).
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dust suppression system compliant with <10mg/m³ emission standards.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A quarry needed to increase production of railway ballast (40mm+20mm) by 40% but faced space constraints preventing simple line duplication.
Solution Implementation of a singletrack mounted primary jaw crushing station feeding a dualprocess circuit with secondary cone crushers dedicated to different final products.
Results Achieved target throughput increase within the existing footprint; automated controls allowed quick switching between ballast production and aggregate chips (20mm), improving contract flexibility.

Urban C&D Recycling Facility Upgrade

Challenge A recycling center processing concrete demolition waste experienced excessive wear from rebar contamination and inconsistent final product due to fluctuating feed composition.
Solution Installation of a heavyduty impact crusher with hydraulic apron adjustment for primary reduction paired with an aggressive doubledeck scalping screen fitted with abrasionresistant media.
Results Tramp metal removal efficiency improved by over 80%; consistent final aggregate quality met strict city specification for road base materials; wear part life increased by an average of 35%.

7. COMMERCIAL CONSIDERATIONS

Our luxury crushing equipment is positioned as a capital investment focused on longterm total cost of ownership reduction.

Pricing tiers are structured around core plant configuration:
Tier A Base Stationary Plant includes primary crusher feeder module basic screening tower stockpile conveyors starting at approximately USD $2 million
Tier B Advanced Automated Plant includes all Tier A features plus secondary/tertiary crushing modules PLC automation system advanced dust suppression
Tier C Custom Turnkey Solution fully engineered sitespecific solution including civil works design installation commissioning training

Optional Features Premium ceramic wear liners for highly abrasive applications remote monitoring telemetry package sound attenuation enclosures

Service Packages Annual Platinum Coverage comprehensive parts labor scheduled inspections Gold Coverage partsonly coverage with discounted labor rates

Financing Options Available through partnered financial institutions including operating leases capital leases longterm rentaltoown structures typically structured over 5year terms

8. FAQ

Q What level of ground preparation is required for installation
A These are substantial permanent structures requiring professional civil engineering foundation design typically involving reinforced concrete piers footings Proper site preparation is critical for longterm alignment stability

Q How does this equipment integrate with our existing conveying system
A Our engineering team can design custom transfer chutes control system interfaces provided we receive detailed drawings of your current conveyor specifications Belt widths speeds heights must be matched

Q What is the expected operational lifespan of the main crusher frame
A With proper maintenance excluding wearable liners the main crusher body frames are designed for a minimum service life exceeding 25 years based on finite element analysis fatigue testing

Q Are operators provided training on the new control system
A Yes comprehensive onsite training for both operators maintenance technicians is included as standard during commissioning covering daily operation troubleshooting basic maintenance procedures

Q Can we source common wear parts like screen cloths locally
A While we recommend genuine parts for optimal performance our modular screen system uses standardized panel sizes that can accommodate certain thirdparty media Basic Vbelts bearings are also industrystandard items