1. PEMBUKAAN PAINPOINT DRIVEN

Are unpredictable breakdowns and inconsistent output crippling your stone quarry's profitability? Managing a primary crushing station is a constant battle against high operating costs and unplanned interruptions. Cabaran utama termasuk:

Excessive Downtime: Unplanned maintenance on crushers or feeders can halt your entire upstream operation, menelan belanja ribuan sejam dalam pengeluaran yang hilang dan buruh terbiar.
Suapan Tidak Konsisten & Crusher Damage: Poorly regulated feed from the apron feeder leads to crusher cavity packing, pemakaian tidak sekata, and potential overload damage, resulting in premature component failure.
Kos Operasi yang Tinggi: Rising energy consumption from inefficient material handling, combined with frequent replacement of wear parts under punishing conditions, menghakis margin anda.
Keselamatan & Risiko Alam Sekitar: Uncontrolled dust emissions at transfer points create health hazards and compliance issues, while manual adjustments expose personnel to moving machinery.

Is there a crushing plant solution that integrates robust primary crushing with intelligent feeding and material flow to deliver predictable tonnage and lower costperton?

2. GAMBARAN KESELURUHAN PRODUK

The Stone Quarry Crushing Plant Assembly is a preengineered, heavyduty stationary crushing circuit designed for highvolume primary reduction of blasted quarry rock (batu kapur, granit, basalt). It integrates key components into a synchronized system for reliable firststage processing.

Aliran Kerja Operasi:
1. Suapan Terkawal: Dump trucks discharge shot rock into a rugged vibrating grizzly feeder (VGFF VGF), which scalps out natural fines and regulates feed to the crusher.
2. Pengurangan utama: Oversize material is conveyed to a highcapacity jaw crusher or primary gyratory crusher for initial size reduction.
3. Pengangkutan Bahan: Crushed product is discharged onto main conveyor systems for transport to secondary crushing or stockpiling.

Skop Permohonan & Batasan:
Skop: Ideal for greenfield quarry development or replacement of aging, inefficient primary circuits. Suited for processing abrasive materials with compressive strengths up to 350 MPa.
Batasan: Tidak direka bentuk sebagai unit mudah alih/mudah alih. Maximum feed size is determined by crusher opening; excessive clay or moisture content without preprocessing may cause handling challenges.

3. CIRI TERAS

Penyumpan Grizzly Bergetar Tugas Berat (VGFF VGF) | Asas Teknikal: Dek keluli berkekuatan tinggi dengan bar berwarna kelabu boleh laras | Faedah Operasi: Mengeluarkan bahan subsize sebelum penghancur, reducing cavity volume and wear while providing consistent, makanan terkawal | Kesan ROI: Meningkatkan daya pemprosesan penghancur sehingga 15% and extends manganese wear life by an estimated 2030%

Struktur BoltTogether Modular | Asas Teknikal: Fabricated steel modules with precisionmachined connection points | Faedah Operasi: Significantly reduces field installation time and cost versus traditional welded designs; membenarkan konfigurasi semula atau penempatan semula pada masa hadapan | Kesan ROI: Can reduce plant assembly time by up to 40%, mempercepatkan pendapatan masa

Centralized Greasing & Sistem Pelincir | Asas Teknikal: Automatik, programmable lubrication points routed from a central station | Faedah Operasi: Ensures critical bearings on the crusher and feeder receive consistent lubrication without manual intervention in hazardous areas | Kesan ROI: Mengurangkan risiko kegagalan galas bencana, reducing unscheduled downtime and associated repair costs

Sistem Penindasan Habuk Bersepadu | Asas Teknikal: Nozzle arrays at key transfer points (feeder discharge, salur masuk/luar penghancur) tied to plant operation | Faedah Operasi: Actively controls respirable dust at the source, meningkatkan keterlihatan tapak dan kualiti udara | Kesan ROI: Lowers compliance risk and reduces housekeeping labor costs

Kawalan Berasaskan PLC & Panel Pemantauan | Asas Teknikal: Industrial programmable logic controller with HMI interface displaying amperage, suhu, and operational status | Faedah Operasi: Provides operators with realtime visibility into plant performance for quick diagnostics and optimal load management | Kesan ROI: Enables proactive maintenance scheduling and prevents minor issues from escalating into major failures

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Persediaan Biasa) | Stone Quarry Crushing Plant Assembly Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Pemasangan Loji| 812 minggu (field welding/fitting) | 46 minggu (pemasangan berbolted) | ~50% lebih pantas |
| Crusher Utilization Rate| ~75% (due to irregular feed)| >85% (optimized VGF regulation)| ~13% increase |
| Penggunaan Tenaga Khusus| Garis asas setiap tan dihancurkan| Hingga 10% lower via optimized load & reduced recirculation| ~10% improvement |
| Pakai Part Life (Crusher Jaw/Mantle)| Standard warranty period| Documented extensions in field data from even feed & reduced tramp metal| 2030% lebih lama |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 400 ke 1,500+ tan per jam (Tph), depending on rock characteristics.
Pilihan Penghancur Utama: Kursus rahang (900x1200mm hingga 1500x2000mm) atau Penghancur Gyratory Utama.
Keperluan kuasa: Jumlah kuasa terpasang biasanya berkisar dari 300 kW kepada 600 kW untuk pemacu utama (penghancur, pengumpan, penghantar). Specific requirements depend on configuration.
Spesifikasi Bahan: Dibuat daripada keluli struktur S355JR; wear surfaces utilize AR400 steel liners; crusher components are highgrade cast steel or manganese.
Dimensi Fizikal: Footprint varies by capacity; a typical 800 TPH plant requires approximately 25m (L) x 15m (W) x 12m (H) foundation space.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Dust suppression system effective up to wind speeds of 8 m/s.

6. SENARIO APLIKASI

Pengembangan Kuari Granit | Cabaran: An existing quarry needed to double primary capacity but had limited space for new foundations and a tight commissioning window of three months. Manual feeding led to frequent jaw crusher bridging. | Penyelesaian: Implementation of a compact Stone Quarry Crushing Plant Assembly with a boltedframe design installed on a prepared pad adjacent to the old plant. The integrated VGF was keyed for aggressive granite feed. | Keputusan: The plant was operational in nine weeks. Crusher bridging incidents were eliminated by the VGF regulation. The site achieved its target of 850 TPH consistently within the scheduled timeframe.

Limestone Aggregate Production for Highway Project | Cabaran: A contractor setting up a temporary quarry faced strict particulate matter (PM10) regulations and needed guaranteed weekly tonnage for asphalt plants. Downtime would delay the entire highway project. | Penyelesaian: A turnkey crushing plant assembly featuring an emphasized dust suppression package with sealed transfer points and automated spray systems was deployed alongside a robust jaw crusher known for low fines generation.| Keputusan: The plant passed all environmental inspections without issue. It maintained availability above 92%, delivering over 35,000 tons of base material weekly as required throughout the project lifecycle.

7. PERTIMBANGAN KOMERSIL

Our Stone Quarry Crushing Plant Assembly solutions are offered in three tiers:

1. Konfigurasi Standard: Termasuk peralatan teras (penghancur, VGFF VGF, penghantar pelepasan), structural frame, basic motor starters, and mandatory safety guards.
2. Konfigurasi Dioptimumkan (Paling Biasa): Adds PLC control panel with basic automation sequences integrated dust suppression system centralized lube system walkways access platforms
3.
4.Konfigurasi Premium: Incorporates advanced condition monitoring sensors variable frequency drives VFDs on feeder motors premium abrasionresistant liners extended warranty package

Optional features include sound attenuation enclosures magnet separators different screen deck media types custom conveyor lengths

Service packages range from annual inspection plans comprehensive multiyear maintenance agreements operator training programs Financing options including leasing capital equipment loans are available through our financial partners subject credit approval

Soalan Lazim

What type of electrical supply is required?
A typical midrange plant requires mediumvoltage supply usually between kV along with stepdown transformer Consult specific technical datasheet detailed requirements

Can this crushing plant assembly be integrated with my existing secondary tertiary circuits?
Yes These plants are engineered standard conveyor interfaces discharge heights Our engineering team can review your layout ensure compatibility material flow specifications

How does this solution improve my overall costperton metric?
Field data shows improvements come multiple areas reduced energy consumption per ton longer wear part life less unplanned downtime higher average throughput All contribute directly lowering your operating expense against each ton produced

What is typical delivery lead time after order placement?
For standard optimized configurations lead time typically ranges months depending capacity complexity Longlead items like custom castings drive timelines Detailed schedule provided upon project initiation

What site preparation is required before delivery?
A level compacted foundation designed bear dynamic load static weight entire plant required Concrete foundations anchor bolts must prepared according supplied civil drawings We provide comprehensive site preparation guide