1. PEMBUKAAN PAINPOINT DRIVEN

Are escalating operational costs and unpredictable downtime eroding your sand and gravel operation's profitability? Cabaran industri biasa memberi kesan langsung kepada pendapatan anda: inconsistent feed material causing frequent plant blockages and unplanned stops; excessive wear on crusher liners and screen cloths from abrasive, unscreened oversize; high energy consumption from processing alreadytospec material; and the significant labor cost of manual clearing and presorting. These issues translate to lost production hours, premature component replacement, and inefficient fuel or power use.

What if you could systematically remove these bottlenecks before they reach your primary processing circuit? Bagaimana a 1520% reduction in crusher liner wear change your annual maintenance budget? The solution lies in effective, highcapacity primary screening—the critical first line of defense for any efficient operation.

2. GAMBARAN KESELURUHAN PRODUK

The HeavyDuty Grizzly Feeder is a rugged, primary scalping unit designed to handle the initial size separation of runofquarry (ROQ) pasir, Kerikil, dan tembak batu. It operates as a robust filter at the very front end of your material handling system.

Aliran Kerja Operasi:
1. Dump & Suapan: ROM material is dumped directly onto the feeder’s heavyduty deck from haul trucks or loaders.
2. Pemisahan Getaran: An aggressive linear vibration moves material forward while allowing subdecksize particles to fall through the grizzly bars.
3. Scalping & Penghalaan: Undersize material (typically sand, Denda, and small gravel) passes through the grizzly openings onto an underlying conveyor for direct bypass to secondary circuits or stockpiling.
4. Oversize Conveyance: Oversize rocks (mis., +6”, +8”) are carried over the bars and discharged into the primary crusher.
5. Perlindungan: The unit absorbs the impact of large rocks, protecting downstream conveyors and crushers from direct shock loading.

Skop Permohonan: Ideal for hightonnage quarry face applications, river dredge feed points, and alluvial deposit operations where feed size is highly variable.
Batasan: Not designed for fine screening or sorting; bar spacing is fixed or mechanically adjustable within a set range. Optimal performance requires controlled feed rates to prevent blinding of the grizzly deck.

3. CIRI TERAS

Pembinaan Dek Tugas Berat | Asas Teknikal: Highstrength, abrasionresistant steel alloy bars with reinforced support frames | Faedah Operasi: Withstands direct impact from large rock (up to 48”+) and continuous abrasion without deformation | Kesan ROI: Reduces structural repair costs by up to 40% over standard decks, extending service life beyond 5 years in severe duty.

Adjustable Grizzly Bar Section | Asas Teknikal: Modular section with manually or hydraulically adjustable bar spacing | Faedah Operasi: Allows operators to change scalp size (mis., from 4” to 8”) di bawah 30 minutes to match deposit changes or product specs | Kesan ROI: Maximizes bypass of spec material, increasing plant throughput by 1025% by relieving the primary crusher.

Dual Mass Vibratory Drive System | Asas Teknikal: Springcoupled system where one mass cancels out dynamic forces on the structure | Faedah Operasi: Generates highstroke linear motion for positive material movement even with sticky clays; reduces transmitted forces to the support structure by up to 95% | Kesan ROI: Lowers foundation costs by up to 50% and reduces energy consumption per ton by approximately 1520%.

BoltIn Replaceable Wear Components | Asas Teknikal: Modular wear shoes, deck liners, and grizzly bars secured with hardened bolts | Faedah Operasi: Enables rapid component replacement during scheduled maintenance without major welding or cutting | Kesan ROI: Cuts downtime for wear part replacement from shifts to hours, improving plant availability.

Variable Speed Drive Control | Asas Teknikal: Frequency inverter controlling vibratory motor speed | Faedah Operasi: Allows finetuning of feed rate and stroke effectiveness for different moisture content and gradations in realtime | Kesan ROI: Optimizes crusher cavity level for maximum reduction efficiency, reducing power spikes and improving overall circuit stability.

Integrated Hopper & Apron Section | Asas Teknikal: Fabricated hopper with bolton apron plates at the feed point | Faedah Operasi: Contains surge loads from truck dumping and provides a controlled feed onto the vibrating deck | Kesan ROI: Eliminates spillage at the feed point and protects dump truck beds from direct impact with grizzly bars.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | HeavyDuty Grizzly Feeder Solution | Kelebihan (% penambahbaikan) |
|||||
| Deck Plate Wear Life | 612 months in abrasive applications | 1824 months with AR400 liners | +100% wear life |
| Kapasiti throughput | Subject to frequent bridging/blinding | Highstroke vibration prevents packing | +30% consistent feed rate |
| Penggunaan tenaga | Fixed speed drives running continuously | Pemacu Frekuensi Boleh Ubah (VFD) pengoptimuman| 18% average power draw |
| Masa Henti Penyelenggaraan | Fullday shutdowns for weld repair | Boltin component replacement |75% component swap time |
| Pakaian kapal penghancur | Direct impact from fines & bahan pelelas | Removal of 80mm fines before crushing |20% on primary mantle/concaves |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Model dependent, daripada 500 TPH berakhir 2,500 TPH of sand & Kerikil.
Keperluan kuasa: Electric vibrator motors ranging from 30 HP ke 100 Hp, typically operating on 480V/3phase/60Hz power.
Spesifikasi Bahan: Main frame ASTM A36 steel; Deck & Grizzly Bars AR400 / Hardox 400 keluli tahan lelasan; Liners Boltin AR500 sections.
Dimensi Fizikal (Model Biasa): Panjang (feed hopper to discharge): ~20 ft; Lebar (over deck): ~8 ft; Ketinggian (underframe): ~6 ft; Berat: ~25,000 lbs.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +50°C (4°F hingga +122°F). Dust seals are standard; optional spray bars available for highmoisture applications.

6. SENARIO APLIKASI

Alluvial Sand & Gravel Pit

Challenge A pit feeding both concrete sand and drainage gravel faced constant plugging at the jaw crusher due to high clay content in wet months, halting production for manual clearing twice per shift.
Solution Installation of a heavyduty grizzly feeder with a VFDcontrolled highamplitude stroke was implemented ahead of the jaw crusher.
Results The aggressive action broke apart clay balls while scalping off oversize cobbles. Crusher plugging incidents dropped by over 90%, increasing effective daily throughput by an average of 180 tons per operating day.

Granite Quarry Processing Shot Rock

Challenge Excessive fines (4") in shot rock were causing rapid wear on cone crusher liners and consuming unnecessary crushing energy while also degrading final product shape.
Solution A twostage grizzly feeder was deployed—a fixedbar section at 8" followed by an adjustablebar section set at 4".
Results Approximately 22% daripada jumlah suapan (The 4"x0" bahan) was bypassed directly to a tertiary circuit conveyor. This reduced load on the primary cone crusher by over onefifth, extending liner life by an estimated three weeks per set and lowering specific energy consumption.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Units are configured based on size/capacity:
Kewajipan Standard (2000 Tph): Includes full Hardox lining, hydraulic bar adjustment,and premium vibrator drives for severeservice mines.

Ciri Pilihan: Hydraulic bar spacing adjustment module; integrated metal detection system; automated lubrication system; customdesigned skid bases or trailer mounts for semiportability; penutup enkapsulasi habuk.

Pakej Perkhidmatan: Threetiered offerings:
1. Basic Warranty covering parts/labor for one year.
2. Extended Protection Plan covering all major structural components plus annual vibration analysis inspection.
3. FullService Agreement including scheduled wear part replacements based on monitored tonnage data.

Financing Options Available through our partners include equipment leasing programs that allow payments out of operational cash flow,tradein valuation services,and projectspecific financing.

8.Soalan Lazim

Q What is required under this equipment?
A A level concrete foundation pad designedto absorb static loads is standard.Field data shows that our dualmass drive system minimizes dynamic forces,but proper anchoring is critical.We provide full foundation drawingswith purchase

Q Can it handle extremely wet or sticky material?
A Yes.The combinationof an aggressive linear strokeand optional deck heating systemsor polyurethanecoated barscan mitigate sticking.Variable speed control allows operators totune themotionfor optimalmaterial flowin changing conditions

Q How does this integratewith my existingprimarycrusherand conveyor system?
A Our engineering team will reviewyour plant layoutto ensureproper interfacingfor height discharge angleand chutework We designfor seamless transferpoints tomaximize flowand minimize spillage

Q Whatis therealistic payback periodon this investment?
A Basedon documented case studiesin similar operations paybackis typically achievedwithin1218 monthsthrough gainsin throughput reducedcrusherwearand lowerdowntime Your specific geologyand product mixwill determineexact figures

Q Arewearparts readily available?
A Yes All criticalwearcomponentsare standardizedstock itemsin our globalnetworkof distribution centers Guaranteedavailabilityis partof ourextendedservice agreements

Q Do you offeronsiteoperator training?
A Yes Comprehensive trainingfor bothoperationsand maintenancecrews is includedwith installation We focuson safeoperation troubleshooting proceduresand daily inspection checklists