1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a stone quarry operation where inconsistent feed, masa henti yang tidak dirancang, and rising operational costs are eroding your margins? Key challenges in primary crushing include:

Masa Henti Berlebihan untuk Penyelenggaraan: 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.
Kos Bahagian Pakai Tinggi: Abrasive feed material leads to rapid wear of crusher jaws, mantel, dan cekung, creating a significant and recurring expense for your parts inventory.
Inconsistent Throughput & Penggredan Produk: Fluctuations in feed size or hardness can cause chokefeeding or poor cavity utilization, resulting in suboptimal tonnage and offspec product that requires recrushing.
Ketidakcekapan Tenaga: Older or poorly configured crushing plants consume excessive power per ton of processed material, memberi kesan secara langsung kepada pendapatan anda apabila kos tenaga meningkat.
Kebimbangan Integriti Struktur: The immense forces generated in a primary crushing station demand a fabricated structure of exceptional durability. Inadequate design can lead to costly frame fatigue, retak, 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. GAMBARAN KESELURUHAN PRODUK: 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, produk mudah alih untuk pemprosesan sekunder.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Runofquarry (ROQ) material is dumped into a rugged vibrating grizzly feeder (VGFF VGF), which scalps out fine undersize material to bypass the crusher, meningkatkan kecekapan.
2. Pengurangan saiz utama: Oversize material is directed into a highcapacity jaw crusher (atau penghancur gyratory, depending on application) di mana ia dimampatkan dan dipatahkan terhadap permukaan tetap dan bergerak.
3. Pengangkutan Produk: Crushed material is discharged onto a heavyduty main product conveyor, transporting it to the next stage of the processing circuit.

Skop Permohonan: Ideal untuk pemprosesan granit tinggi, basalt, batu kapur, dan agregat kasar yang lain. Suited for permanent installation in largescale quarry operations.

Batasan: Tidak direka untuk aplikasi mudah alih atau mudah alih. Maximum feed size is determined by crusher model selection; extremely sticky or claybound materials may require additional preprocessing.

3. CIRI TERAS

Modular Fabricated Base Frame | Asas Teknikal: CADoptimized, highstrength steel weldment with internal reinforcing diaphragms | Faedah Operasi: Provides an unwavering foundation that maintains precise crusher and motor alignment under cyclical loading | Kesan ROI: Eliminates costly realignment downtime and extends bearing & drive component life by up to 30%.
Platform Penyelenggaraan Bersepadu & Akses | Asas Teknikal: Ergonomic design per ISO safety standards with nonslip grating, guardrails, and strategic service points | Faedah Operasi: Your crew can perform routine inspections, liner checks, and maintenance tasks safely and efficiently | Kesan ROI: Reduces service time by an average of 25%, mengurangkan kos buruh dan meningkatkan ketersediaan loji.
Penyumpan Grizzly Bergetar Tugas Berat (VGFF VGF) Seksyen | Asas Teknikal: Robust deck construction with replaceable grizzly bars and highinertia vibrator motors | Faedah Operasi: Effectively removes fines while absorbing direct impact from haul truck dumping | Kesan ROI: Increases primary crusher capacity by preventing chokefeeding with fines; melindungi penghancur daripada beban kejutan.
Pelincir Berpusat & Sistem hidraulik | Asas Teknikal: Manifolded system with failsafe indicators and easyaccess service ports | Faedah Operasi: Membolehkan selamat, bersih, and consistent lubrication of all critical crusher bearings from a single location | Kesan ROI: Standardizes maintenance procedures prevents lubrication failures which are a leading cause of major component damage.
Cable Management & Utility Routing | Asas Teknikal: Prefabricated steel conduits and trays integrated into the plant structure | Faedah Operasi: Protects power and control cables from damage dust contamination ensuring reliable electrical supply | Kesan ROI: Minimizes electrical faults reduces installation time onsite by providing a plugandplay wiring infrastructure.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Amalan Standard Industri | Penyelesaian Loji Penghancur Bertauliah ISO kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| 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. |
| Pemasangan Di Tapak & Masa Pentauliahan| 46 weeks for foundation work assembly alignment testing. Modular design with preassembled sections; laseraligned at factory. 50% onsite labor time reduced project risk. |
| Ketersediaan Operasi (Masa aktif) ~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. |
| Penggunaan Tenaga setiap Tan Diproses| Varies widely older drives directonline starting.| Engineered drive train efficiency softstart systems optimized kinematics.| Data lapangan menunjukkan 815% pengurangan penggunaan tenaga tertentu |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Configurable for throughputs from 400 ke 2 000+ Ton metrik sejam (Tph)
Pilihan Penghancur Utama: Kursus rahang (900 x 1200mm hingga 1500 x 2000mm) atau Penghancur Gyratory Utama
Feeder Grizzly: Lebar daripada 1 200mm ke 2 400mm; panjang dari 4 500mm ke 7 500mm
Keperluan kuasa: Jumlah kuasa terpasang biasanya antara 250 kw 600 kW dependent on configuration
Spesifikasi Bahan: Main frame fabricated from S355JR structural steel; wear surfaces utilize AR400 abrasionresistant steel liners
Dimensi Fizikal (tipikal): 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. SENARIO APLIKASI

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 PERTIMBANGAN KOMERSIL

Our ISOcertified fabrication process ensures transparent costing predictable delivery schedules

Peringkat Harga
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 Soalan Lazim

Apakah tahap penyediaan tapak yang diperlukan sebelum penghantaran?
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

Apakah masa utama biasa dari penempatan pesanan hingga pentauliahan?
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