1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menguruskan operasi agregat volum tinggi dan menghadapi kesesakan berterusan yang menghadkan keuntungan anda? Untuk pengurus loji dan kontraktor kejuruteraan, a 250300tph stone crushing plant represents a critical production tier, yet common operational challenges can significantly erode its return on investment.

Inconsistent Throughput: Unplanned downtime from equipment failure or blockages can cost thousands per hour in lost production, preventing you from reliably meeting demanding project schedules or supply contracts.
Kos Penyelenggaraan Tidak Berjadual: Premature wear on crusher liners, skrin, and conveyors due to improper equipment selection or flow design leads to frequent stoppages and high spare part expenditures.
Bentuk produk yang lemah & Penggredan: Inability to precisely control final product cubicity and size distribution results in material rejection, reduced market value, and wasted processing energy.
Kerumitan Operasi yang Tinggi: Plants that require excessive manual intervention for adjustment or material handling increase labor costs and elevate the risk of human error.

Persoalan utama ialah: how do you achieve a consistent 250300 tons per hour output with predictable operating costs and maximum asset uptime? Penyelesaiannya bukan hanya terletak pada mesin individu, but in a fully engineered 250300tph kilang penghancur batu designed as an integrated system.

2. GAMBARAN KESELURUHAN PRODUK

Penyelesaian ini adalah pegun, hardrock crushing and screening plant engineered for continuous, highvolume production of aggregates (05mm, 510mm, 1020mm, 2031.5mm, dll.). It is designed for primary contractors and largescale aggregate suppliers requiring reliable output for road base, agregat konkrit, atau balast kereta api.

Aliran Kerja Operasi:
1. Penghancuran utama: Bahan suapan besar (≤750mm) is reduced to ≤200mm by a robust primary jaw crusher or gyratory crusher.
2. Sekunder & Penghancuran tertiari: Bahan dihantar ke penghancur kon(s) untuk pengurangan selanjutnya, ensuring proper particle shape. A dedicated tertiary stage may be included for precise shaping.
3. Pemeriksaan & Pengelasan: Multipledeck vibrating screens accurately separate crushed material into specified product sizes.
4. Pengendalian bahan & Stok: A network of belt conveyors transfers both finished products and oversize material back to crushers (reka bentuk litar tertutup).
5. Penindasan Debu: Integrated spray systems at transfer points control dust emissions to meet environmental standards.

Skop Permohonan & Batasan:
Skop: Ideal untuk memproses granit, basalt, batu kapur, dan agregat kasar yang lain. Suitable for large quarry operations or major infrastructure project support.
Batasan: Not designed for portable applications. Feed material hardness must be within the specified compressive strength range of the selected crushers. Memerlukan asas yang stabil dan bekalan kuasa berasaskan grid.

3. CIRI TERAS

Reka Bentuk Loji Modular | Asas Teknikal: Pra-kejuruteraan, substruktur bolttogether | Faedah Operasi: Mengurangkan masa pemasangan tapak sehingga 40% compared to traditional weldedonsite designs | Kesan ROI: Pentauliahan yang lebih pantas mempercepatkan penjanaan hasil; simplifies future reconfiguration or relocation.

Sistem Kawalan Proses Pintar | Asas Teknikal: Centralized PLC with touchscreen HMI and motor management | Faedah Operasi: Membolehkan pemantauan singleoperator terhadap keseluruhan aliran, provides realtime alerts for deviations (mis., feed blockage, high bearing temp) | Kesan ROI: Optimizes power consumption per ton; prevents catastrophic failures through early warning diagnostics.

Skrin Bergetar Tugas Berat dengan Dek Poliuretana | Asas Teknikal: High Gforce screening action combined with wearresistant polyurethane panels | Faedah Operasi: Achieves higher screening efficiency (>95%) with less blinding; significantly longer deck life than wire mesh | Kesan ROI: Reduces replacement part frequency by an average of 60% over wire cloth; ensures consistent product gradation.

Pelarasan Hidraulik & Clearing on Crushers | Asas Teknikal: Integrated hydraulic systems for CSS adjustment and chamber clearing | Faedah Operasi: Allows quick product size changes without downtime tools; automates clearing of stallcausing blockages in minutes | Kesan ROI: Memaksimumkan ketersediaan tumbuhan; increases operational flexibility to switch between product specs rapidly.

Centralized Greasing & Sistem Pelincir | Asas Teknikal: Automated lubrication pumps feeding critical bearing points across multiple machines | Faedah Operasi: Ensures optimal lubrication intervals are maintained without manual intervention across hardtoreach points | Kesan ROI: Memanjangkan hayat perkhidmatan galas sehingga 30%, directly reducing maintenance labor hours and component replacement costs.

Sistem Penghantar Tali Pinggang Bertetulang | Asas Teknikal: Hightensile EP belting with impact beds at loading zones and heavyduty idlers rated for CEMA E4 duty | Faedah Operasi: Eliminates premature belt damage from heavy loads; reduces spillage along the line | Kesan ROI: Lowers longterm conveyor maintenance costs by minimizing belt replacements and idler failures.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Tumbuhan Biasa) | Penyelesaian Loji Penghancur Batu 250300tph ini | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Keseluruhan Ketersediaan (Masa Jalan yang Dijadualkan) | ~85% 90% (Downtime for adjustments/clearing) |>92% 95% (Via hydraulic systems & reka bentuk yang mantap) |>5% Bertambah |
| Penggunaan Kuasa setiap Tan Diproses| Garis dasar (100%) |8% 12% (Pemacu yang dioptimumkan & efficient crushing chambers)| Hingga 12% Pengurangan |
| Liner Wear Life in Secondary Crusher| Berbeza mengikut jenis batu |15% 25% (Advanced chamber design & metalurgi)| Hingga 25% Sambungan |
| Kecekapan Saringan (Produk Akhir)| ~90%92% |>95%97% (HighG screens & antiblinding decks)| ~5 Point Increase |
| Pemasangan & Masa Pentauliahan| Full project timeline |30%40% (Modular preassembly)| Hingga 40% Pengurangan |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti Direka: 250 300 Ton metrik sejam (varies based on feed material hardness and final product size).
Pilihan Penghancur Utama: Kursus rahang (900x1200mm) or Gyratory Crusher with feed opening suited for ≤750mm rock.
Peringkat Menengah/Tertiari: One or two Cone Crushers with heavyduty design (~250kW motor each).
Peringkat Saringan: Two to three units of TripleDeck Inclined Vibrating Screens (~22kW each).
Keperluan Kuasa: Total installed power approximately 800kW 1000kW. Requires stable industrial grid connection.
Spesifikasi Bahan Utama: Primary frame constructed from heavyduty steel profiles; Wear plates in hoppers from AR400 steel; Tali pinggang penghantar dinilai untuk minimum PIW=1000.
Jejak Fizikal (Anggaran): Length ~80m –100m x Width ~25m –35m (bergantung susun atur). Total weight ~350 –450 tons.
Julat Operasi Persekitaran: Designed for ambient temperatures from 20°C to +45°C with appropriate lubrication options. Dust emission control meets standard regulatory limits via spray systems.

6. SENARIO APLIKASI

LargeScale Quarry Expansion

Cabaran:
A regional quarry needed to increase annual output by over one million tons but was constrained by an aging twostage plant prone to breakdowns causing over two weeks of unplanned downtime annually.
Penyelesaian:
Implementation of a turnkey threestage stationary stone crushing plant designed for reliable operation at an average throughput of approximately280tph.
Keputusan:
Plant availability increased consistently above93%. Annual production target was met within eleven months postinstallation while reducing maintenance labor costs by an estimated18%.

Projek Pembinaan Lebuhraya Utama

Cabaran:
A contractor required onsite production of over500，000 tons of various specification aggregates within a tight24month schedule，with strict control over particle shape（flakiness index）for asphalt layers。
Penyelesaian：
Deployment of this modular stone crushing plant featuring primary jaw，kon sekunder，and tertiary cone crushers configured specifically for shaping。
Keputusan：
The project achieved consistent daily output exceeding270tph。Final aggregate cubicity exceeded local DOT specifications，eliminating material rejection。The modular nature allowed rapid demobilization upon project completion。

7．COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around core configuration complexity：

• Base Configuration Tier：Includes primary jaw，kon sekunder，saringan asas，and essential conveyors。Designed as the most costeffective entry point。
• HighEfficiency Tier：Adds dedicated tertiary shaping stage，polyurethane screen decks，and basic PLC control system。Recommended balance between performance investment。
• Premium Automation Tier：Includes fullfeatured process automation（PLC/HMI），centralized lube/grease systems，and premium wear component packages。Targets operations prioritizing maximum uptime minimal manpower。

Ciri Pilihan：Dust suppression bag filter systems（beyond basic sprays），onboard power generation packages，extended warranty coverage on major components。

Pakej Perkhidmatan：Available as annual preventative maintenance contracts providing scheduled inspections priority spare parts access fixedcost coverage on key wear items。

Pilihan Pembiayaan：Flexible commercial leasing structures are available typically spanning36to60months allowing preservation capital expenditure budgets。

8．FAQ

S1：Can this stone crushing plant configuration handle very wet or sticky feed material？
A1：While capable processing moderately damp rock significant clay content can reduce screening efficiency throughput。For such applications we recommend specifying additional screen deck heating systems或scalping prescreens part optional package。

S2：What level operator training required？
A2：The intelligent control system simplifies operation；however comprehensive training provided covering daily startup/shutdown procedures basic troubleshooting interface navigation ensure your team confident managing system。

S3：How does solution address longterm spare parts availability？
A3：We utilize industrystandard components bearings motors etc。from globally recognized suppliers ensuring parts procurement remains straightforward throughout equipment lifespan detailed bill materials recommended spares list provided commissioning。

S4：What typical delivery lead time turnkey installation？
A4：For standard configurations lead time ranges from20to28weeks order placement depending current manufacturing load site readiness factors modular design reduces subsequent onsite installation period approximately8to10weeks experienced crew。

S5：Are these plants suitable producing railway ballast？
A5：Yes specifically when configured tertiary shaping stage proper screen media produce controlled topsize product excellent particle integrity meets most stringent rail ballast specifications field data confirms consistent production highquality ballast materials。

S6 ：What key factors determine final choice between jaw gyratory primary crusher？
A6 ：Selection depends primarily feed material characteristics required capacity Gyratory generally offers higher throughput similar size handles more abrasive rock slightly higher initial cost Jaw crusher often selected lower capital cost simpler maintenance profile smaller footprint Detailed analysis your specific rock type recommended during planning phase 。

S7 ：Does commercial proposal include civil works foundation design？
A7 ：Our scope supply typically includes detailed foundation layout drawings anchor bolt plans necessary facilitate local civil contractor construction works full turnkey projects including civil works can be arranged under separate contract 。