1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang meningkat dan masa henti yang tidak menentu menghakis margin pengeluaran agregat anda? Untuk pengurus loji dan kontraktor kejuruteraan, the core challenges in material reduction often stem from inefficient primary crushing. Titik kesakitan biasa termasuk:
Masa Henti Berlebihan untuk Penyelenggaraan: Frequent liner changes and unplanned repairs on your primary crusher halt your entire processing line, menelan belanja beribu-ribu sejam dalam pengeluaran yang hilang.
Pengurangan Saiz Suapan Tidak Konsisten: Variable feed material causes chokefeeding or erratic performance, leading to downstream bottlenecks in your secondary and tertiary circuits.
Kos Operasi yang Tinggi: Soaring energy consumption per ton of processed material and premature wear part failure directly impact your bottomline profitability.
Limited Flexibility & Skalabiliti: A fixed crushing solution cannot adapt to changing feed materials or increased production targets without significant capital reinvestment.

Is your primary crushing station the bottleneck in your operation? Apakah yang akan a 1520% reduction in costperton mean for your annual budget? The solution lies in specifying a highperformance, reliable primary crushing station engineered for maximum uptime and efficiency.

2. GAMBARAN KESELURUHAN PRODUK: PRIMARY CRUSHING STATION

A Primary Crushing Station is a complete, semifixed or modular system designed for the first stage of size reduction in quarrying, perlombongan, and largescale construction applications. Its function is to accept runofmine or blasted feed material (up to 1000mm+) and reduce it to a conveyable size for transport to downstream processing.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Dump trucks deposit material into a robust vibrating grizzly feeder (VGFF VGF).
2. Pengurangan utama: The VGF scalps fines and directs oversize material into a highcapacity jaw crusher or gyratory crusher for initial compression breaking.
3. Pengendalian bahan: Crushed product is discharged onto a main conveyor belt system for transport to the next stage of processing.

Skop Permohonan: Ideal for hightonnage hard rock (granit, basalt), bijih kasar, and recycled concrete operations requiring throughput from 500 ke atas 2,500 tph.

Batasan: Not suitable as a standalone solution where final product specification is required; must be integrated with secondary/tertiary crushing and screening circuits. Site requires adequate space for setup and feed access.

3. CIRI TERAS

Patented Quarry Jaw Design | Asas Teknikal: Kinematik yang dioptimumkan & reinforced chamber geometry | Faedah Operasi: Achieves higher reduction ratios with lower wear rates, minimizing frequency of liner changes | Kesan ROI: Reduces wear part inventory costs by an estimated 18% and increases crusher availability

HeavyDuty Modular Base Frame | Asas Teknikal: Pra-kejuruteraan, bolttogether substructure with integral walkways | Faedah Operasi: Enables faster site installation and future relocation without heavy fabrication work | Kesan ROI: Cuts installation time by up to 40%, accelerating timetoproduction

Intelligent Variable Speed Feeder Control | Asas Teknikal: PLCdriven VGF with loadsensing technology | Faedah Operasi: Automatically regulates feed rate to prevent crusher overload (choke) or underutilization (starve) | Kesan ROI: Optimizes power draw, improving energy efficiency by up to 12% and maximizing throughput

Sistem Penindasan Habuk Bersepadu | Asas Teknikal: Strategically placed nozzle arrays with solenoid control tied to crusher operation | Faedah Operasi: Actively suppresses dust at key transfer points only when needed, conserving water | Kesan ROI: Ensures regulatory compliance while reducing water consumption by approximately 30%

Centralized Greasing & Lube Station | Asas Teknikal: Singlepoint connection for automated lubrication of all major bearings | Faedah Operasi: Membolehkan selamat, routine maintenance from one location in under 15 minit | Kesan ROI: Enhances bearing life by ensuring consistent lubrication, preventing costly failures

HighStrength Discharge Conveyor | Asas Teknikal: Channel frame design with impact bars at loading zone | Faedah Operasi: Withstands continuous heavy loads and direct impact from crushed discharge | Kesan ROI: Reduces belt damage and spillage, lowering conveyor maintenance costs

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Our Primary Crushing Station Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Adanya (Masa Jalan yang Dijadualkan) | 8892% | 95%+| +47% Penambahbaikan |
| Kos setiap Tan (Pakai bahagian) | Garis dasar (100%)| 85%| 15% Pengurangan |
| Pemasangan & Masa Pentauliahan| 810 minggu| 56 minggu| ~40% Faster Deployment |
| Penggunaan tenaga (kWj/tan)| Berbeza mengikut jenis batu| Hingga 12% Lebih rendah| Verified by field telemetry |
| Masa Min Antara Kegagalan (MTBF)| ~1,200 jam| >1,600 jam| +33% Reliability Increase |

5. SPESIFIKASI TEKNIKAL

Jenis penghancur: HeavyDuty Single Toggle Jaw Crusher
Pembukaan suapan: 1,400mm x 1,200mm (55" x 47")
Saiz suapan maksimum: 1,000mm (39")
Tetapan sampingan tertutup (CSS) Julat: 150mm 300mm (6" 12")
Julat Kapasiti: Hingga 900 1,200 tph (bergantung kepada ketumpatan bahan & CSS)
Kuasa memandu: Tier IV Final / Stage V compliant dieselelectric or direct electric drive options; 200 kW main crusher motor.
Structural Fabrication: Hightensile steel plate with abrasionresistant liners at critical wear points.
Station Footprint (L x W): Approximately 28m x 8m (92' x 26').
Julat Suhu Operasi: 25°C hingga +45°C (13°F hingga +113°F) with appropriate fluid specifications.

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Challenge A granite producer needed to increase plant throughput by 35% but was constrained by an aging primary crusher causing 10 hours of weekly unplanned downtime.
Solution Implementation of our modular Primary Crushing Station with the patented jaw design and intelligent feeder control.
Results Station commissioned in 5 minggu. Mencapai daya pengeluaran yang berterusan sebanyak 950 tph with availability exceeding 96%. Costperton reduced by 18%, paying back the investment in under 14 bulan.

LargeScale Infrastructure Development

Challenge A civil engineering contractor required a temporary highvolume crushing solution for processing excavated basalt on a major highway project, with strict dust control regulations.
Solution Deployment of a mobileprimarycrusherconfigured station with integrated dust suppression and quickrelocation capability.
Results The station processed over 2 million tons of material onsite across three different project phases. Dust emissions remained within compliance limits without slowing production, eliminating offsite hauling costs.

7. PERTIMBANGAN KOMERSIL

Our Primary Crushing Stations are offered in three capabilitybased tiers:
Essential Tier: Highreliability core system ideal for consistent feed materials. Base pricing structured around required throughput capacity.
Peringkat Prestasi: Includes advanced features like intelligent feeder control, automated lubrication,and enhanced dust suppression for operations targeting optimal costperton.
Elite Tier: Fully customized stations with premium components,surge capacity design,and predictive maintenance telemetry integration for megaprojects.

Optional features include onboard power generation sets,magnet systems for tramp metal removal,and heated operator stations.Service packages range from basic commissioning support to comprehensive Planned Maintenance Agreements covering parts,buruh,dan pemeriksaan berjadual.Pilihan pembiayaan termasuk perjanjian pajakan modal,struktur sewaan sendiri yang disesuaikan,dan pembiayaan berasaskan projek melalui rakan kongsi bertauliah.

8. Soalan Lazim

Q1 Is this Primary Crushing Station compatible with my existing secondary plant?
A Yes.The discharge conveyor speed heightand load capacity are engineered during specificationto match your downstream receiving hopper or screen feed conveyor ensuring seamless integration.

Q2 What is the expected operational impact during liner changes?
A Our jaw design features hydraulic setting adjustmentand reversible liners.Field data shows liner changeout can be completed typically within one standard shift minimizing production loss comparedto older designs requiring longer downtime

Q3 Are there financing options available that alignwith our project cash flow?
A Yes.We offer several commercial structures including operating leases that preserve capitaland milestonebased payment plans tiedto commissioningand performance verification

Q4 How does the intelligent feeder control handle highly variable feed material?
A The PLC system monitors crusher power drawin realtime automatically slowingor speedingthe feeder tomaintain optimal chamber loading This protects the crusherfrom tramp metal eventsand mitigates the effectsof size variation

Q5 What trainingis providedfor our maintenance crew?
A Comprehensive trainingis included covering daily inspections routine maintenance proceduresand wear part replacement protocols Documentation includes detailed manualsand troubleshooting guides