1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a quarry ballast operation where inconsistent product gradation, penjanaan denda yang berlebihan, and unplanned maintenance are eroding your margins? The primary challenges in producing highspecification railway ballast and construction aggregate are clear:
Gradation Inconsistency: Failure to consistently meet the strict particle size distribution (JPA) for railway ballast (mis., AREMA, DALAM 13450) leads to product rejection, rerushing, dan kehilangan pendapatan.
Pakai tinggi & Kos downtime: Sifat kasar granit, basalt, and limestone rapidly degrades crusher liners and impact elements, causing frequent stoppages for component replacement and escalating your costpertonne.
Penjanaan Denda Berlebihan: Improper crushing action creates an overabundance of 10mm material, which is waste in ballast production. This reduces your yield of premium, inspec produk.
Keamatan Tenaga: Inefficient crushing chambers and drive systems result in high power consumption per tonne of final product, memberi kesan secara langsung kepada perbelanjaan operasi.
Plant Inflexibility: Fixedconfiguration crushers cannot adapt to varying feed material hardness or changing product specification demands without significant downtime for reconfiguration.

How do you increase the yield of premium quarry ballast while controlling wear costs and ensuring plant uptime? The answer lies in selecting purposeengineered quarry ballast crushing equipment.

2. GAMBARAN KESELURUHAN PRODUK

This datasheet details our range of stationary and mobile primary jaw crushers and secondary cone crushers engineered specifically for highvolume quarry ballast production. These machines are designed to transform blasted rock into precisely graded, agregat kubus.

Aliran Kerja Operasi:
1. Pengurangan utama: Blasted feed (biasanya 750mm) is introduced into a heavyduty jaw crusher. The deep crushing chamber and aggressive nip angle facilitate initial size reduction to a manageable 250mm product.
2. Sekunder & Penghancuran tertiari: The primary crushed material is then fed into a cone crusher operating in a closed circuit with a sizing screen. This stage is critical for achieving the final cubical shape and exact gradation.
3. Saiz & Recirculation: Oversize material from the screening deck is recirculated back to the cone crusher (operasi litar tertutup), while inspec quarry ballast is conveyed to stockpile.

Skop Permohonan & Batasan:
Skop: Ideal for medium to hard abrasive rock (Granit, Basalt, Kuarzit). Suitable for both largescale stationary quarries and mobile contract crushing setups requiring relocation.
Batasan: Not designed for very soft or nonabrasive rock (mis., kapur), where alternative crusher types may be more appropriate. Saiz suapan maksimum ditentukan oleh model penghancur primer khusus yang dipilih.

3. CIRI TERAS

Pelarasan CSS Hydroset | Asas Teknikal: Hydraulic piston adjusts the closedside setting (CSS) di bawah beban | Faedah Operasi: Allows operators to finetune product gradation in minutes without stopping the crusher, responding to realtime feed changes | Kesan ROI: Eliminates production downtime for mechanical shim adjustments, increasing annual throughput by up to 7%

Liner Wear Compensation | Asas Teknikal: Automated system maintains CSS via hydraulic positioning as liners wear | Faedah Operasi: Delivers consistent product gradation over the full liner life without manual intervention | Kesan ROI: Maintains premium product yield and reduces risk of offspec production by an average of 15%

MultiAction Crushing Chamber | Asas Teknikal: Optimized chamber geometry combines attrition, compression, and interparticle crushing | Faedah Operasi: Promotes grainongrain breakage for superior particle shape with lower fines generation | Kesan ROI: Increases saleable quarry ballast yield by 812% compared to standard chambers

Galas Tugas Berat & Reka Bentuk Kerangka Utama | Asas Teknikal: Forged alloy steel mainframe with oversized spherical roller bearings | Faedah Operasi: Sustains high shock loads from uncrushable material and ensures longterm structural integrity | Kesan ROI: Extends major component service life beyond 20,000 jam, reducing total cost of ownership

Sistem Automasi Berasaskan PLC | Asas Teknikal: Programmable Logic Controller with loadandlevel sensors for chokefed operation | Faedah Operasi: Mengekalkan tahap rongga optimum secara automatik, maximizing throughput and protecting the crusher from damage | Kesan ROI: Optimizes power draw efficiency by up to 10% and prevents costly overload events

ServiceFriendly Design | Asas Teknikal: Hydraulic tools for backing compound removal and topserviceable liner change design | Faedah Operasi: Reduces liner changeout time by over 50% compared to traditional bolton designs | Kesan ROI: Lowers labor costs per maintenance event and increases plant availability

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Penyelesaian Penghancur Kuari Ballast Kami Kelebihan Didokumentasikan |
| : | : | : |
| Hasil Produk (+22mm 63mm) | ~6570% of feed mass typically within spec range based on industry averages >75% consistently achieved through optimized chamber design >75% consistently achieved through optimized chamber design |
| Kehidupan Pelapik (Kon Sekunder) ~500700 operating hours in abrasive granite >850 operating hours demonstrated in field trials >850 operating hours demonstrated in field trials |
| Energy Consumption ~0.8 1.1 kWh/tonne for secondary crushing ~0.65 0.9 kWh/tonne measured at multiple sites ~0.65 0.9 kWh/tonne measured at multiple sites |
| Gradation Consistency Standard deviation of ±8% on key sieve sizes Standard deviation tightened to ±4% via automation Standard deviation tightened to ±4% via automation |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: daripada 200 tan sejam (mobile configurations) ke atas 1,200 tph (stationary primary/secondary plants).
Keperluan kuasa: Primary jaw units from 110400 kw; Secondary cone units from 132315 kw. All drives compatible with VSDs for soft start capability.
Spesifikasi Bahan: Designed for unconfined compressive strength (UCS) hingga 350 MPa. Crusher wear parts manufactured from Mn18Cr2 or equivalent highgrade manganese steel.
Dimensi Fizikal (Contoh Loji Mudah Alih): Panjang: ~19m; Lebar: ~3m; Ketinggian: ~4m; Berat Operasi: ~48 tonnes.
Julat Operasi Persekitaran: Standard units rated for 20°C to +40°C ambient temperature. Dust suppression system connections standard on all models.

6. SENARIO APLIKASI

Railway Ballast Production Plant Challenge A national rail infrastructure contractor faced recurring penalties due to flaky particle content exceeding network standards from their existing cone crushers Solution Implementation of a tertiary cone crusher with a multiaction chamber specifically tuned for cubicity Results Particle elongation index (EI) reduced from 28% to below 15%, ensuring full compliance AREMA 4A spec Firstyear yield increased by approximately €180k due reduced waste fines

Granite Quarry Expansion Challenge A large granite quarry needed higher throughput without expanding their primary circuit footprint or increasing energy costs Solution Replacement of two older secondary crushers with a single highcapacity cone model featuring advanced automation Results Throughput increased by 22% while specific energy consumption fell by18%. Payback period on equipment was achieved within14 months through increased sales volume

Contract Crushing Operator Challenge A mobile crushing contractor required rapid setup teardown between sites while maintaining precise output gradations across varying geology Solution Deployment trackmounted jaw cone plant featuring hydraulic setting adjustment quick release conveyor systems Results Site mobilization time reduced by40%. Operators can recalibrate CSS hydraulically between sites ensuring spec compliance across different projects without downtime

7 PERTIMBANGAN KOMERSIL

Our quarry ballast crushing equipment is offered across several tiers:
Konfigurasi Standard: A costeffective package including core machine basic automation dust suppression
Pakej HighAvailability: Includes upgraded wear monitoring telemetry extended warranty on major components
Turnkey Plant Design Engineering services site layout optimization integration with existing conveyors screens

Optional features include advanced rock level sensors automatic lubrication systems remote monitoring portals Service packages range from scheduled maintenance plans comprehensive life cycle contracts Financing options include capital purchase finance leases operational leases structured align payments project cash flow

8 Soalan Lazim

What if my feed material hardness varies significantly throughout the quarry face?
The hydroset system allows quick CSS adjustment compensate variations Automation maintains choke feed ensuring consistent performance shape across different strata

How does this equipment integrate with my existing screening washing circuits?
Crushers are designed standard discharge heights conveyor widths Interface points clearly defined Our engineering team can provide integration drawings ensure compatibility

What typical operational training required for my team?
We provide comprehensive onsite training covering operation basic troubleshooting liner changes Most crews proficient within three five working days

Are wear parts readily available what expected lead times?
We maintain regional inventory critical wear parts Average lead time consumables like mantles concaves is under72 hours supported service network

What financing structures available beyond outright purchase?
We offer several models including3660 month finance leases which may offer tax benefits well as rental purchase agreements tailored seasonal cash flows