1. PEMBUKAAN PAINPOINT DRIVEN

Managing a private label quarry operation in Lagos presents distinct challenges that directly impact your bottom line and market competitiveness. Are you grappling with inconsistent aggregate quality that leads to product rejection? Are production bottlenecks and frequent equipment downtime causing you to miss critical delivery windows for construction projects? Is the high operational cost of running aging, inefficient crushing and screening lines eroding your profit margins on every ton sold? The pressure to supply certified, specificationgrade aggregates for Lagos’s infrastructure boom demands a reliable, highoutput solution. How do you transform your site from a cost center into a consistent, profitable source of highdemand construction materials?

2. GAMBARAN KESELURUHAN PRODUK

The Private Label Quarry Plant adalah lengkap, modular crushing and screening system engineered for the production of specification aggregates under your own brand. This turnkey solution is designed for quarry owners aiming to control quality, maximize yield, and optimize operational costs.

Aliran Kerja Operasi:
1. Pengurangan utama: Raw feed from the quarry face is fed into a robust primary jaw crusher for initial size reduction.
2. Penghancuran Menengah/Tertiari: Material is then processed through a cone crusher or impact crusher circuit to achieve the desired cubicity and gradation.
3. Saringan Ketepatan: Multipledeck vibrating screens accurately separate crushed material into specified aggregate sizes (mis., 3/4", 1/2", pasir tajam, habuk batu).
4. Stok & Memuatkan: Sized aggregates are conveyed to dedicated stockpiles for qualitycontrolled storage and direct loading onto trucks.

Skop Permohonan: Ideal for establishing new private label quarries or retrofitting existing sites in granite, batu kapur, and other hard rock formations common in SouthWest Nigeria. This system is configured for the production of aggregates for concrete, asfalt, Pangkalan jalan, and drainage applications.

Batasan: Not designed for soft rock or unconsolidated material mining without significant configuration changes. Site requires adequate space for plant layout and stockpiles.

3. CIRI TERAS

Reka Bentuk Loji Modular | Asas Teknikal: Bolttogether, skidmounted sections | Faedah Operasi: Significantly reduces civil works and installation time onsite, membolehkan pentauliahan lebih cepat. | Kesan ROI: Cuts project startup time by up to 40%, mempercepatkan pendapatan masa.

HighEfficiency Cone Crusher | Asas Teknikal: Hydroset system and optimized crushing chamber | Faedah Operasi: Maintains consistent product gradation and shape with minimal manual adjustment, even as liner wear occurs. | Kesan ROI: Improves yield of premiumgrade aggregates by an average of 15% and reduces waste.

MultiStage Screening Circuit | Asas Teknikal: Tripledeck, highfrequency vibrating screens with tensioned rubber decks | Faedah Operasi: Provides precise separation of up to four product sizes simultaneously, ensuring strict adherence to NIS/BS standards. | Kesan ROI: Eliminates costly reprocessing of offspec material and maximizes saleable product from each ton of feed.

Sistem Kawalan PLC Berpusat | Asas Teknikal: Automated process control with touchscreen HMI | Faedah Operasi: Allows operators to monitor and adjust the entire flow from a single station, optimizing throughput and identifying bottlenecks instantly. | Kesan ROI: Reduces labor requirements per ton produced and minimizes human error in process control.

HeavyDuty Apron Feeder | Asas Teknikal: Overlapping manganese steel flights driven by rugged reduction gears | Faedah Operasi: Provides consistent, regulated feed to the primary crusher under all load conditions, including sticky or wet material common in Lagos’s climate. | Kesan ROI: Prevents crusher chokefeed events that cause downtime and protects downstream equipment from surge loads.

Dust Suppression System Integration| Asas Teknikal: Pressurized water spray nozzles at key transfer points| Faedah Operasi: Actively controls fugitive dust at source, promoting a safer working environment and supporting compliance with environmental considerations.| Kesan ROI: Mitigates operational delays due to environmental complaints and reduces wear on machinery from abrasive dust.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Persediaan Biasa) | Private Label Quarry Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Tonnage per ManHour| 810 Tons/Hour/Operator| 1416 Tons/Hour/Operator| +60% Kecekapan buruh |
| Hasil Produk (Bahan Spec)| ~7580% of total feed| Secara konsisten 8892% daripada jumlah suapan| +15% Saleable Product |
| Masa Min Antara Kegagalan (Crushing Circuit)| ~450 Operating Hours| >700 Waktu Operasi (didokumenkan)| +55% Kebolehpercayaan |
| Penggunaan Tenaga setiap Tan| Garis dasar (100%)| Measured at approx. 82% daripada garis dasar| 18% Power Cost |
| Plant Reconfiguration Time| Weeks for major changes| Days due to modular design & PLC presets| 70% Downtime |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti Direka: 150 400 tan per jam (configurable based on feed material and final product mix).
Penghancur utama: Kursus rahang, Feed Opening up to 1200mm x 800mm.
Penghancur sekunder: Hydraulic Cone Crusher with multiple chamber options.
Unit Saringan: (2) Tripledeck Vibrating Screens; Screen area of 18m² each.
Keperluan kuasa: Jumlah kuasa terpasang lebih kurang 450 650 kw; configured for stable grid or heavyduty generator set operation.
Spesifikasi Bahan Utama: Highwear components (pelapik, apron) use AR400 steel or OEMmanufactured manganese; structural frames are heavygauge carbon steel.
Dimensi Fizikal (Modular Units): Individual modules designed for standard transport; max module dimensions ~12m L x 3m W x 4m H.
Julat Operasi Persekitaran: Designed for ambient temperatures of 15°C to 45°C; humidity up to 95%; dust suppression rated for effective operation.

6. SENARIO APLIKASI

Concrete Aggregate Production Challenge:

A Lagosbased quarry supplying readymix plants faced frequent rejection of its coarse aggregate due to poor cubicity and excessive flakiness index (<15), compromising concrete strength specifications.

Penyelesaian:

Implementation of a Private Label Quarry Plant centered on a highefficiency cone crusher with a cubicalshaped crushing chamber profile was implemented alongside precise screening decks calibrated specifically for coarse aggregate sizing bands required by major batching plants operating within Lekki Free Zone environs etcetera

Keputusan:

Aggregate cubicity improved consistently above >85%, meeting all EN & BS standards while eliminating product rejections entirely within six months postinstallation thereby securing longterm supply contracts worth over ₦500 million annually

Pangkalan jalan & Asphalt Chipping Production Challenge:

An established quarry near Ibadan expressway struggled with low yield (<70%)of premium asphalt chippings(10mm &14mm)and inconsistent gradation leading them unable compete effectively against imported alternatives despite lower logistical costs

Penyelesaian:

Deployment focused heavily upon multistage screening circuit featuring specialized screen media combined tertiary impact crusher finetuning particle shape resulting dualflow system capable producing both superior road base materials alongside specification chippings simultaneously

Keputusan:

Yield increased dramatically reaching averages around ninety percent(90%)for chipping products allowing company successfully bid supplying major federal highway rehabilitation projects across Ogun State region increasing annual revenue forty percent yearoveryear

Pertimbangan Komersial

Equipment pricing tiers vary based on capacity configuration starting at approximately ₦180 million Naira ($120k USD equivalent)for basic setup reaching upwards ₦700 million($465k USD equivalent)for fully automated highcapacity systems inclusive auxiliary equipment like excavators etcetera Optional features include advanced metal detection systems automated lubrication packages remote monitoring telematics Service packages offered comprise scheduled maintenance plans critical spare parts kits comprehensive operator training programs Financing options available through partner institutions include leasepurchase agreements structured over three five years terms tailored cash flow needs Nigerian businesses

Soalan Lazim

Q What existing infrastructure needed install this plant?
A You require suitable land area approximately one hectare accessible heavy trucks reliable electrical connection threephase supply water source dust suppression Minimal civil works needed due modular nature foundations simple concrete pads

Q How quickly can become operational after delivery?
A With all preparations complete typical commissioning period ranges between four six weeks depending site conditions complexity chosen configuration includes thorough operator training period

Q Can this system produce both sharp sand plaster sand?
A Yes specific configurations incorporate VSI(Impak aci menegak)crusher sand manufacturing module producing precisely graded manufactured sand alternative natural river sand meeting strict concrete specifications

Q What ongoing technical support available?
A Comprehensive service network includes local technical team Lagos supported regional depot stocked common wear parts offering scheduled maintenance emergency breakdown response within agreed service level agreements(SLA)

Q Are there financing options available Nigerian companies?
A Yes we collaborate several financial institutions provide asset financing solutions including leasepurchase structures help manage capital expenditure improve cash flow typically requiring thirty percent down payment balance spread across term

Q How ensure plant remains efficient over time?
A Our recommended scheduled maintenance plan includes regular wear part inspection lubrication system checks performance data analysis via PLC telematics allowing proactive maintenance preventing unscheduled stoppages