1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a midtolarge scale aggregate operation and facing consistent pressure to meet project deadlines while controlling capital and operational expenditure? The challenges of a 250300tph stone crushing plant are significant. Inconsistent feed material causes unexpected wear and downtime on critical components. Bottlenecks in one crushing stage throttle the entire line’s output, leaving capacity unrealized. Rising energy costs directly erode profit margins on every ton produced. Tambahan pula, frequent maintenance interrupts production schedules, and configuring a plant for multiple product specifications often requires manual adjustments and costly delays.

How do you achieve reliable 300tonperhour output without excessive maintenance overhead? Can your plant adapt to varying feed hardness and size without sacrificing final product gradation? Is your current solution delivering the expected return on investment through sustained availability and low costperton?

2. GAMBARAN KESELURUHAN PRODUK

Produk ini adalah lengkap, stationary 250300tph turnkey stone crushing and screening plant designed for highvolume production of aggregates for road base, konkrit, dan asfalt. It is engineered for primary contractors and quarry operators requiring consistent, specificationgrade output.

Aliran Kerja Operasi:
1. Penghancuran utama: Suapan besar (≤750mm) dikurangkan oleh penghancur rahang yang teguh atau impak utama.
2. Sekunder & Penghancuran tertiari: Material is conveyed to cone crushers or secondary impactors for further size reduction and shaping.
3. Pemeriksaan: Multipledeck vibrating screens precisely separate crushed material into required product sizes (mis., 05mm, 510mm, 1020mm).
4. Pengendalian bahan: A network of conveyors with centralized control transfers material between stages and to final stockpiles.
5. Penindasan Debu: Sistem semburan bersepadu di titik pemindahan mengawal pelepasan zarah, ensuring environmental compliance.

Skop Permohonan & Batasan:
Skop: Sesuai untuk batu keras (granit, basalt), batu kapur, and river gravel applications. Suited for permanent installation in large quarry sites or major infrastructure project batching plants.
Batasan: Tidak direka bentuk sebagai peralatan mudah alih atau separuh mudah alih. Feed size and material abrasiveness must align with configured crusher chamber selections for optimal performance.

3. CIRI TERAS

Reka Bentuk Skid Modular | Asas Teknikal: Dipasang terlebih dahulu, steelframed substructures | Faedah Operasi: Mengurangkan masa pemasangan di tapak sehingga 40%, ensures precise factory alignment of motors and drives | Kesan ROI: Pentauliahan yang lebih pantas mempercepatkan penjanaan hasil; standardized modules simplify future maintenance.

Sistem Kawalan Proses Pintar | Asas Teknikal: Automasi berasaskan PLC dengan algoritma perkongsian beban | Faedah Operasi: Optimizes crusher feed rates in realtime to prevent choking or running empty; monitors power draw for peak efficiency | Kesan ROI: Reduces energy consumption per ton by an estimated 815% dan meminimumkan ralat operator.

HeavyDuty Wear Component Package | Asas Teknikal: Bar tamparan highchrome, manganese steel jaws/concaves, reinforced screen meshes | Faedah Operasi: Memanjangkan selang perkhidmatan dengan 3050% in abrasive applications, maintains consistent product gradation longer | Kesan ROI: Lowers costperton for wear parts and reduces downtime frequency for component changeouts.

MultiStage Dust Control Integration | Asas Teknikal: Strategically placed spray nozzles with solenoid valves tied to conveyor operation | Faedah Operasi: Effectively suppresses dust at each transfer point, improving site visibility and operator health | Kesan ROI: Mitigates risk of environmental noncompliance fines and reduces cleanup labor.

Centralized Greasing & Sistem pelinciran | Asas Teknikal: Automated pump system with distribution lines to key bearing points | Faedah Operasi: Ensures critical bearings receive correct lubrication on schedule without manual intervention | Kesan ROI: Prevents premature bearing failure, a leading cause of unplanned downtime.

HighCapacity Vibrating Screens with Deck Access System | Asas Teknikal: Large screening area with adjustable throw; integrated walkways & platform | Faedah Operasi: Maximizes screening efficiency; menyediakan selamat, easy access for mesh inspection and replacement | Kesan ROI: Improves final product quality control and enhances worker safety during routine checks.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (250300tph Loji) | This 250300tph Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Ketersediaan Loji | 8588% (termasuk penyelenggaraan yang dirancang) | 92%+ (engineered design) | +47% masa beroperasi |
| Penggunaan tenaga (kWj/tan)| Berbeza secara meluas; often not optimized per stage| Managed via intelligent load control| Hingga 15% reduction demonstrable |
| Wear Life on Abrasive Rock| Standard manganese/chrome components| Premium alloy selection & chamber optimization| +30% peningkatan purata |
| Pemasangan & Masa Pentauliahan| 812 weeks onsite assembly| ~57 weeks (modular skid design)| ~40% pengurangan |
| Konsisten Penggredan Produk| Manual feed adjustment leads to variance| Automated setting regulation (ASRitype systems)| Variance improved by up to 25% |

5. SPESIFIKASI TEKNIKAL

Kapasiti Throughput Direka: 250 300 Ton metrik sejam (varies based on feed material hardness & Pengagihan saiz).
Pilihan Penghancur Utama: Kursus rahang (900x1200mm) atau Penghancur Impak Utama (Φ1600x2000mm).
Penghancur Menengah/Tertiari: Two units of Hydraulic Cone Crushers (mis., HPC315).
Screening Stations: Two units of TripleDeck HeavyDuty Vibrating Screens (2400x6000mm).
Jumlah Kuasa yang Dipasang: Kira -kira 800 950 kw.
Spesifikasi Bahan Utama: Main frame structure fabricated from Q345B steel; wear liners use Mn18Cr2 or equivalent highgrade alloys.
Jejak Tumbuhan Keseluruhan (L x W): ~120m x 85m (layout can be customized).
Julat Operasi Persekitaran: Direka untuk suhu ambien 20°C hingga +45°C; dust emission control meets standard regulatory limits (<20mg/m³ at property boundary).

6. SENARIO APLIKASI

Highway Construction Base Course Production | Cabaran: A national infrastructure project required consistent supply of three graded aggregates for road base layers from highly abrasive granite. The existing plant struggled with rapid wear and inconsistent sizing, threatening project timelines.| Penyelesaian: Implementation of this heavyduty configured plant featuring cone crushers with automated settings control and premium wear packages.| Keputusan: Achieved sustained output of 280tph. Wear part life increased by over 35%, reducing changeout downtime. Product gradation consistency met strict highway authority specifications throughout the contract.

Commercial Limestone Quarry Expansion | Cabaran: A quarry expanding its market needed to increase finished product range without adding separate processing lines or excessive manual sorting.| Penyelesaian: Installation of this multistage plant with precise secondary/tertiary crushing circuits and highefficiency multideck screens.| Keputusan:The plant reliably produces five distinct products simultaneously—from coarse aggregate to manufactured sand—at a combined rate exceeding 270tph, enabling entry into new concrete and asphalt mix markets.

7. PERTIMBANGAN KOMERSIL

Our approach provides clarity in investment planning:

Peringkat Harga: We offer three standard configurations:
Penting: Core crushing & screening modules for reliable singleproduct output.
Advanced: Includes automation systems, enhanced dust control, wider conveyor specification.
Premium: Full turnkey package with premium wear materials package extended warranty coverage

Ciri Pilihan & Naik taraf: Specific options include automated metal detection/rejection systems advanced rockonrock shaping chambers additional sound attenuation enclosures remote monitoring telematics packages

Pakej Perkhidmatan: Choose from annual maintenance contracts providing scheduled inspections guaranteed spare parts delivery priority technical support Extended warranty plans are available covering major structural components

Pilihan Pembiayaan: We work with established financial partners offer flexible leasing arrangements milestonebased project financing solutions tailored capital expenditure plans

8.Soalan Lazim

1.Q:What if our feed rock hardness exceeds the standard design parameters?
A:The plant's core structural design accommodates high loads but we conduct a detailed feed material analysis during quotation For extremely hard or abrasive materials we specify upgraded wear component alloys chamber geometries ensure designed throughput longevity

2.Q How does this plant manage fluctuations in incoming feed size?
A The intelligent process control system regulates feeder speeds based realtime crusher motor load preventing choking This combined surge pile capacity before primary crusher smooths out typical frontend loader variation

3.Q What typical timeframe expected from order placement commissioning?
A For standard configuration lead time manufacturing shipping approximately months Onsite installation commissioning modular skid design typically requires weeks depending local civil works readiness

4.Q Are spare parts readily available longterm?
A Yes We maintain global inventory strategic wear parts provide guaranteed stockholding agreements as part service packages All major mechanical electrical components internationally standardized brands ensuring supply chain redundancy

5.Q Can existing equipment integrated into new plant?
A Potentially yes An initial audit your current conveyors screens can determine compatibility integration feasibility often possible especially material handling equipment reducing overall project cost

6.Q What ongoing operational staffing requirements?
A The automated central control system allows efficient operation primary operators monitoring stations Additional personnel required routine mechanical checks stockpile management but labor intensity significantly lower versus manually controlled plants

7.Q What key factors influence final price quotation?
A Final pricing determined specific equipment selection required options degree site preparation needed local regulatory compliance costs shipping logistics destination Comprehensive site survey forms basis fixedprice turnkey proposal