1. PEMBUKAAN PAINPOINT DRIVEN

Are escalating operational costs and unpredictable downtime eroding your sand and gravel margins? Your wash plant is the heart of your operation, yet common inefficiencies directly impact profitability. Consider these persistent challenges:
Inefficient Fines Removal: Inconsistent clay and silt rejection leads to offspec product, increased pond maintenance, and potential loss of premium material to waste.
Air Tinggi & Penggunaan kuasa: Traditional scrubbing and washing methods require excessive water recirculation and horsepower, creating unsustainable utility costs and environmental footprint.
Frequent Component Wear: Abrasive feed material accelerates wear on shafts, galas, dan pelapik, resulting in unplanned maintenance stops and high parts replacement budgets.
Limited Feed Flexibility: Can your system handle variable feedstock—from cemented aggregates to sticky claybound gravel—without choking or losing efficiency?
Angkasa & Setup Constraints: Are you sacrificing processing capacity because your current equipment layout is inefficient or your site footprint is limited?

Soalan utama untuk pengurus kilang adalah ini: how can you increase tons per hour of inspec material while systematically reducing cost per ton in water, tenaga, dan penyelenggaraan?

2. GAMBARAN KESELURUHAN PRODUK

The Log Washer is a core mineral processing machine designed for the tough duty of breaking down, menyental, and cleaning heavily cemented aggregates or gravel contaminated with soluble clays, soft rock, and other deleterious materials. It is not a simple rinsing tool but an aggressive attrition machine.

Aliran Kerja Operasi:
1. Suapan & Retention: Contaminated feed (mis., claybound gravel) dimasukkan ke dalam tab condong. Reka bentuk dwi aci memastikan pergerakan bahan yang positif sambil menyediakan masa pengekalan yang berpanjangan.
2. Agresif Attrition: Aci bermutar balas yang dipasang dengan dayung NiHard mencipta tindakan menyental yang sengit. Zarah-zarah bahan dikikis dengan kuat antara satu sama lain, menghancurkan aglomerat tanah liat dengan berkesan dan memecahkan simen lembut.
3. Perpisahan & Pelepasan: Bahan yang digosok dibawa naik ke serong dengan tindakan dayung. Pelepasan agregat yang dibersihkan di hujung yang tinggi, manakala denda yang dibebaskan dan air proses yang kotor dialirkan keluar melalui bendung limpahan di hujung bawah.

Skop Permohonan & Batasan:
Skop: Ideal untuk agregat tahan lama yang memerlukan penyentalan yang kuat (batu dihancurkan, Kerikil), bahan yang sukar dikendalikan dengan tanah liat plastik, dan makan dengan bahan cemar batu lembut atau syal.
Batasan: Not suitable for friable or degradable materials that will break down into excess fines. Requires a steady feed rate; performance diminishes with significantly undercapacity loading.

3. CIRI TERAS

HeavyDuty Tub Design | Asas Teknikal: Continuous weldment from abrasionresistant steel plate | Faedah Operasi: Withstands constant abrasive wear without fatigue cracking, memastikan integriti struktur jangka panjang | Kesan ROI: Eliminates midlife tub replacement costs; data lapangan menunjukkan 4060% longer service life versus standard plate construction

NiHard Paddle & Shaft System | Asas Teknikal: Cast NiHard paddles on a forged alloy steel shaft with replaceable bolton log washers | Faedah Operasi: Maximizes abrasion resistance where wear is highest; simplifies maintenance by allowing individual paddle replacement | Kesan ROI: Reduces downtime for shaft/paddle service by up to 70%; lowers longterm inventory cost for wear parts

Dual Shaft Gear Drive | Asas Teknikal: Synchronized helical gear drive housed in an oilbath chamber | Faedah Operasi: Provides positive timing of counterrotating shafts for consistent material movement; eliminates chain drive stretch and breakage risks | Kesan ROI: Reduces driverelated downtime to near zero; gearbox efficiency yields up to 15% lower power consumption compared to equivalent chaindriven units

Adjustable Overflow Weirs | Asas Teknikal: Manually adjustable weir plates along the discharge end | Faedah Operasi: Operators can finetune retention time and slurry density in realtime based on feed variation | Kesan ROI: Optimizes product grade control, reducing offspec yield by an average of 812% as reported by plant managers

Modular Bearing Cartridges | Asas Teknikal: Dimeterai, prealigned roller bearing cartridges mounted externally to the tub | Faedah Operasi: Isolates critical bearings from water ingress and contamination; allows for cartridge replacement without major shaft disassembly | Kesan ROI: Memanjangkan hayat perkhidmatan galas sebanyak 3x; reduces critical path repair time from hours to minutes

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (ChainDriven Log Washer) | Our Log Washer Solution (GearDriven) | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Drive System Efficiency | Chain & Sprocket (~85% efficient) | Enclosed Helical Gear Drive (~98% efficient) | ~15% Lower Power Draw |
| Masa Min Antara Kegagalan (memandu) | 4,000 6,000 jam (chain stretch/breakage) | 20,000+ jam (gearbox service interval) | >300% Bertambah |
| Abrasion Wear Life (Paddles) | Standard AR Steel Castings (~1,200 hrs avg.)| NiHard Castings with optimized profile (~2,200 hrs avg.)| ~80% Peningkatan |
| Masa Henti Penyelenggaraan (Bearing Service)| 68 jam (disassembly required) | <2 jam (cartridge swap) | ~70% Reduction |
| Feed Size Flexibility Max Recommended| 4" (100mm) due to chain stress limitations| 6" (150mm) due to hightorque gear drive| 50% Larger Capacity

5. SPESIFIKASI TEKNIKAL

Kapasiti Julat Model: 50 400 Tph (Tan per jam), depending on material density and contamination level.
Keperluan kuasa: 75 400 HP dual motor configuration across model range. Electrical supply must match motor nameplate specifications (mis., 460V/60Hz/3Ph).
Spesifikasi Bahan: Tub constructed from ¾” AR400 abrasionresistant steel. Paddles are Grade III NiHard cast iron. Aci adalah keluli aloi palsu.
Dimensi Fizikal (Model LW200): Overall Length: 28'. Overall Width: 9'. Ketinggian Pelepasan: 12'. Anggaran Berat: 48,000 lbs.
Julat Operasi Persekitaran: Designed for continuous outdoor operation in temperatures from 20°C to +50°C (4°F hingga +122°F). Sealed components protect against dust and moisture ingress.

6. SENARIO APLIKASI

Aggregate Producer – Sticky Clay Contamination

Cabaran: A Midwest gravel pit faced significant clay contamination that coated aggregate, failing washed concrete sand specifications and clogging dewatering screens daily.
Solution Implementation of a hightorque Log Washer ahead of the classification deck.
Results The intense attrition stripped >95% of clay coatings. Keluaran loji meningkat sebanyak 22%, pond maintenance frequency decreased by twothirds.

Pembinaan & Kitar semula perobohan

Cabaran: Processing recycled concrete with residual mortar required effective liberation without overcrushing the valuable aggregate.
Solution Integration of a Log Washer after primary crushing to scrub recycled concrete feed.
Results Achieved consistent cleanliness meeting DOT specs for base material.Reduced manual sorting labor by an estimated $45k annually.

Sand Processing Plant Upgrade

Challenge An existing operation using only screens could not remove soluble clays leading to poor sand quality rejected by ready mix customers.
Solution A compact Log Washer was installed in the circuit postscreening.
Results Produced a premium mason sand meeting ASTM C144 specifications opening new markets Plant revenue increased by approximately $180k in the first year.

7 PERTIMBANGAN KOMERSIL

Peringkat Harga Peralatan distrukturkan di sekitar kapasiti pemprosesan:
Tier I Standard Duty Units Up To TPH range ideal for satellite pits or lower volume operations includes base gear drive NiHard paddles
Tier II Heavy Duty Units TPH range most common configuration includes all Core Features modular bearings adjustable weirs
Tier III Custom High Capacity Units TPH designed for major greenfield plants includes custom tub lengths specialized paddle configurations

Optional Features Premium urethane lined tub sections for less abrasive applications variable frequency drives VFDs for precise speed control automated grease lubrication systems remote monitoring sensors

Service Packages Three tiers available Bronze Annual inspection parts discount Silver Includes annual inspection priority parts shipping Gold Comprehensive planned maintenance program including annual bearing service

Pilihan Pembiayaan Tersedia melalui institusi rakan kongsi termasuk pajakan modal operasi pajakan atau struktur pinjaman syarat biasa bulan boleh distrukturkan untuk memadankan corak aliran tunai bermusim

8 Soalan Lazim

Q Apakah peralatan huluan yang diperlukan sebelum mesin basuh balak
A Pencuci kayu balak memerlukan suapan terkawal lazimnya daripada tong lonjakan atau tali sawat Ia harus mengikuti penghancuran utama tetapi mendahului skrin saiz akhir Untuk hasil terbaik pastikan saiz suapan tidak melebihi cadangan pengeluar

S Bagaimanakah ini memberi kesan kepada keseluruhan sistem pengurusan air saya
A Walaupun pembasuh balak yang berkesan menggunakan air, mereka mengurangkan beban pepejal ke kolam pengendapan anda dengan ketara Ujian industri menunjukkan penyingkiran buburan yang cekap reka bentuk kami boleh mengurangkan kitaran pengorekan kolam berbanding kaedah menyental yang kurang cekap.

Q Can this unit replace my existing scrubber or trommel screen
A It depends on your material For heavy clays it often serves as a superior primary scrubbing unit For simple rinsing it may be over engineered A site audit can determine optimal circuit placement

Q What is the typical installation timeframe
A For a standard unit foundation preparation electrical hookup mechanical assembly typically requires working days assuming all site utilities are prepared Installation supervision services are available

Q Adakah alat ganti sedia ada
A Yes Critical wear parts paddles shafts bearing cartridges are stocked regionally Average emergency parts shipment lead time is business days within continental US

Q What financing options apply if Im upgrading an existing plant
A Peningkatan selalunya layak untuk struktur kewangan yang berbeza termasuk pinjaman penambahbaikan teknologi Kami boleh menyediakan dokumentasi yang menggariskan penjimatan keuntungan kecekapan yang diunjurkan yang boleh membantu dalam mendapatkan pembiayaan

Q Adakah latihan operator disediakan
Ya Latihan komprehensif yang meliputi penutupan permulaan prosedur pelarasan pemantauan rutin asas penyelesaian masalah disertakan dengan pembelian Sesi latihan di tapak tambahan tersedia di bawah pakej perkhidmatan kami