1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a premium stone quarry operation where inconsistent feed material, masa henti yang tidak dirancang, and rising operational costs are eroding your profit margins? Cabaran utama termasuk:

Masa Henti Berlebihan untuk Penyelenggaraan: Frequent liner changes and component wear in primary crushing stages can halt your entire processing line for days, menelan belanja beribu-ribu sejam dalam pengeluaran yang hilang.
Inconsistent Final Product Cubicity: Poorly shaped aggregate from inefficient crushing reduces the market value of your output and can lead to product rejection by highspecification clients in the construction and infrastructure sectors.
Kos Operasi yang Tinggi: Soaring energy consumption from inefficient crushing chambers and the constant expense of replacing wear parts directly impact your bottom line.
Had Kebolehskalaan: Can your current setup handle planned increases in production tonnage or adapt to different feed materials without a complete system overhaul?

Persoalan utama ialah: how do you achieve higher throughput of premium, inspec aggregate while systematically reducing cost per ton?

2. GAMBARAN KESELURUHAN PRODUK

This product description details our advanced Premium Stone Quarry Crushing Plant, a stationary or semimobile solution engineered for highvolume primary and secondary reduction of hard rock (granit, basalt, kuarzit). The system is designed as the core of your aggregate production.

Aliran Kerja Operasi:
1. Menghancurkan Rahang Utama: Bahan suapan besar (sehingga 1200mm) is reduced to a manageable size by a heavyduty jaw crusher.
2. Penghancuran Kon Sekunder: The output is conveyed to a highperformance cone crusher for further reduction and critical shaping of the aggregate.
3. Pemeriksaan & Menyusun: Material is classified by size on heavyduty vibrating screens.
4. Recirculation & Penghancuran tertiari: Oversize material is recirculated through the cone crusher or a tertiary impact crusher for final shaping.
5. Stok: Pecahan bersaiz betul dihantar ke stok simpanan yang ditetapkan.

Skop Permohonan & Batasan:
Skop: Ideal for hightonnage production of railway ballast, Pangkalan jalan, agregat konkrit, and asphalt chips from hard, abrasive rock formations.
Batasan: Not optimized for soft or nonabrasive materials like limestone where an impactcentric circuit may be more efficient. Memerlukan stabil, prepared site foundations and substantial electrical power infrastructure.

3. CIRI TERAS

Pelarasan CSS Hydroset | Asas Teknikal: Hydraulic piston adjustment of the crusher’s closedside setting (CSS) | Faedah Operasi: Operators can adjust product size or clear blockages in under 60 seconds from a central control panel, tanpa campur tangan manual. | Kesan ROI: Mengurangkan masa henti untuk pelarasan rutin sebanyak lebih kurang 85%, meningkatkan ketersediaan operasi tahunan.

Ruang Penghancur Berbilang Lapisan | Asas Teknikal: Optimized cavity design with varying compression zones | Faedah Operasi: Produces a higher percentage of wellshaped, cubic end product while reducing flakiness index by up to 30% compared to standard chambers. | Kesan ROI: Increases the market value of your output and reduces waste material.

Patented Wear Part Alloy | Asas Teknikal: Manganese steel alloy with titanium carbide inclusions | Faedah Operasi: Extends liner life in primary and secondary crushers by 4060% under abrasive conditions. | Faedah Operasi: Fewer changeouts reduce labor costs and inventory requirements for spare parts.

Sistem Kawalan Proses Pintar | Asas Teknikal: PLCbased automation with load and pressure sensors | Faedah Operasi: Continuously monitors crusher load, optimizing feed rate via variable frequency drives (VFDS) on conveyors to prevent choking or running empty. | Kesan ROI: Improves energy efficiency by up to 15% and protects equipment from damage.

Laluan Modular & Maintenance Platform Design | Asas Teknikal: pasang siap, bolton access systems | Faedah Operasi: Menyediakan selamat, 360degree access for inspection and maintenance tasks, complying with global safety standards. | Kesan ROI: Reduces time required for routine checks and liner changes, enhancing worker safety.

Centralized Greasing & Sistem Pelincir | Asas Teknikal: Automated lubrication delivery to multiple bearing points from a single station | Faedah Operasi: Ensures critical bearings receive correct lubrication on schedule, eliminating manual greasing errors. | Kesan ROI: Memanjangkan hayat perkhidmatan galas dengan purata 25%, mencegah kegagalan yang mahal.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Premium Stone Quarry Crushing Plant Solution | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Adanya (Masa aktif) | ~85% (perhentian yang dirancang/tidak dirancang) |>92% (reka bentuk sistem) |>8% penambahbaikan |
| Kos setiap Tan (Pakai bahagian)| $0.50 $0.70/ton |2030% pengurangan |>20% penambahbaikan |
| Kecubisan Produk (% Cubic Grains) |>75% |>90% |>15% penambahbaikan |
| Penggunaan tenaga (kWj/tan)| Berbeza mengikut jenis batu |1015% via smart controls |>10% penambahbaikan |
| Masa Tukar Pelapik (Utama)| 2436 jam masa anak kapal|50% penambahbaikan |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti Reka Bentuk: 400 – 1,200 tan sejam (Tph), depending on configuration and feed material hardness.
Pilihan Penghancur Utama: Kursus rahang, feed opening up to 1200mm x 800mm.
Pilihan Penghancur Menengah/Tertiari: Hydraulic Cone Crushers with multiple chamber options.
Keperluan kuasa: Total installed plant power typically ranges from 500kW to 1.2MW; requires mediumvoltage connection (3.3kV 6.6kV).
Spesifikasi Bahan Utama: Dibuat daripada keluli struktur S355JR; wear parts in premium manganese steel with optional ceramic composites for extreme abrasion.
Dimensi Fizikal (Persediaan Biasa): Panjang lebih kurang. 45m x Width approx. 22m x Height approx. 15m (tidak termasuk penghantar stok simpanan).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; sistem penindasan habuk disertakan; pelepasan bunyi yang mematuhi <85 db(A) at perimeter with enclosures.

6. SENARIO APLIKASI

Granite Quarry Supplying National Infrastructure Projects

Cabaran: A major quarry needed consistent, highvolume output of railway ballast and concrete aggregate meeting strict geometric specifications. Their existing plant produced excessive flaky material, leading to product downgrading.
Penyelesaian: Implementation of a turnkey Premium Stone Quarry Crushing Plant featuring a multilayer cone crusher chamber and intelligent process control.
Keputusan: Mencapai daya pengeluaran yang berterusan sebanyak 850 TPH with product cubicity consistently above 92%. The plant reduced recirculating load by over 25%, lowering specific energy consumption.

Basalt Aggregate Producer Expanding Market Share

Cabaran: Unplanned downtime due to wear part failures and manual CSS adjustments was limiting output during peak construction season, missing key delivery windows.
Penyelesaian: Installation of our crushing plant featuring the Hydroset system and automated centralized lubrication.
Keputusan: Reduced scheduled maintenance stops for liner changes by over half increased annual production volume by an estimated18%. Wear part life extended by over40%, significantly lowering cost per ton

HighSilica Quartzite Operation

Challenge Extreme abrasiveness of feed material was causing unsustainable wear part costs every six weeks leading to frequent full plant stoppages
Solution Configuration focused on our patented wear part alloy liners across all crushing stages combined with optimal chamber geometry
Results Achieved liner life extensionto1416 weeks between change outs This directly translated into three fewer full shutdowns annually saving an estimated500 hours of lost production time

PERTIMBANGAN KOMERSIL

Our Premium Stone Quarry Crushing Plants are offered in three primary tiers:

1 Standard High Performance Plant Includes core jaw cone screening modules automation basic dust suppression Priced as acapital turnkey solution
2 Advanced Configuration Adds features like tertiary crushing stage advanced process controlwith remote monitoring extended wear package Available via outright purchaseor long term lease
3 Custom Engineered Solution For unique geologies or space constraints fully customized design integrationwith existing infrastructure Priced on project scope

Optional Features Hybrid drive systems solar power assist advanced particle shape analysisin line remote diagnostic portals extended warranty packages

Service Packages We offer tiered annual service agreements covering everythingfrom scheduled inspectionsand parts supplyto full site maintenance crews These agreements provide predictable operational budgetingand guaranteed response times

Financing Options Available through partner institutions including equipment loans operating leasesand lease topurchase arrangements tailoredto matchyour cash flow requirements typically rangingfrom36to72month terms

Soalan Lazim

Q What if my existing primary feeding systemis not compatiblewithyour plant design
A Our engineering team conductsa pre bid site auditand can designinterface hoppers conveyorsor apron feedersas part ofthe solution ensuring seamless integrationwithyour current upstream extractionand downstreamprocessing equipment

Q How does this plant manage variationsin feed rock sizeand hardness throughoutthe quarry face
A The intelligent process control system automatically adjusts feeder rates basedon real time crusher motor load preventing overloads The hydraulic setting adjustment allows quick compensationfor hardness changes maintaining consistent product size

Q What isthe typical installationand commissioning timelinefora standard configuration
A Fora prepared site foundation deliveryis typically within20 weeksof order Commissioningand operator training conductedby our engineers requiresan additional23 weeks dependingon plant complexity We provide detailed project planning support

Q Adakah jaminan prestasi disediakan
A Yes we provide contractual guaranteesfor rated throughput power consumption key wear part lifetimeunder defined operating conditionsand final product gradation These are basedon agreed upon test protocols usingyour specific feed material samples

Q What trainingis providedforour operationsand maintenance staff
A Comprehensive trainingis included covering daily operation troubleshooting basic maintenance proceduresandsafety protocols This includes both classroom sessionsat our facilityand hands on instructionat your site during commissioning Documentationis providedin multiple languages