1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang meningkat dan masa henti yang tidak menentu menghakis keuntungan kuari anda? Untuk pengurus loji dan kontraktor kejuruteraan, the crushing plant is the linchpin of production, yet it is often the source of persistent challenges. Halangan operasi biasa termasuk:
Masa Henti Berlebihan untuk Penyelenggaraan: Perubahan pelapik yang kerap, kegagalan galas, dan kerosakan yang tidak dijangka menghentikan pengeluaran, menelan belanja beribu-ribu sejam dalam kehilangan output dan buruh.
Penggredan Produk Tidak Konsisten: Fluctuations in final aggregate size lead to product rejection, reduced premium pricing, dan bahan mentah terbuang.
Penggunaan Tenaga Tinggi: Inefficient crushing chambers and drives result in unsustainable power costs, memberi kesan secara langsung kepada metrik costperton anda.
Degradasi Bahagian Pakai Pantas: Abrasive stone varieties cause premature wear on crusher components, leading to high spare parts inventories and frequent replacement cycles.
Inflexible Plant Configuration: Fixed layouts struggle to adapt to changing feed material or market demand for different aggregate specifications.

Is your current setup a constant source of reactive maintenance and cost overruns? Penyelesaiannya bukan hanya terletak pada mesin, but in a correctly specified and robustly fabricated loji penghancur kuari batu.

2. GAMBARAN KESELURUHAN PRODUK

A loji penghancur kuari batu is a permanent or semipermanent processing system engineered to reduce blasted rock into specified aggregate sizes. As a fabricator, we design, jurutera, and construct these integrated systems tailored to your geological feedstock and production targets.

Aliran Kerja Operasi:
1. Pengurangan utama: Dumpfed blasted rock is reduced by a primary crusher (mis., rahang rahang) kepada saiz yang boleh diurus untuk menyampaikan.
2. Sekunder & Penghancuran tertiari: Material is further processed through cone or impact crushers to achieve intermediate sizes and final product shaping.
3. Saiz & Menyusun: Vibrating screens separate crushed material into precise product streams (mis., ¾” cip, ½” agregat).
4. Pengendalian bahan: Rangkaian penghantar, pengumpan, and transfer points moves material efficiently between stages.
5. Stok & Pemuatan: Finished aggregates are conveyed to segregated stockpiles for inventory or direct loadout.

Skop Permohonan & Batasan:
This equipment is designed for highvolume stationary processing of abrasive materials (granit, basalt, batu kapur). It is not suitable for smallscale portable operations or nonmineral materials without significant configuration review.

3. CIRI TERAS

Our fabrication approach focuses on engineered durability and operational efficiency.

Reka Bentuk Skid Modular | Asas Teknikal: Gelincir keluli struktur terpasang dengan laluan pejalan kaki dan tangga bersepadu | Faedah Operasi: Mengurangkan masa pemasangan medan sehingga 40%, memastikan penjajaran komponen kilang yang tepat | Kesan ROI: Lower labor costs for installation/relocation; pentauliahan yang lebih pantas menjana pendapatan lebih cepat
HeavyDuty Chute & Liner Fabrication | Asas Teknikal: Computermodeled wear patterns with AR400/500 steel liners at critical impact zones | Faedah Operasi: Minimizes material plugging and wearthrough; extends service intervals by 23x | Kesan ROI: Reduces unplanned downtime for chute repair; lowers longterm liner inventory costs
Centralized Greasing & Sistem Pelincir | Asas Teknikal: Manifolded automatic lubrication lines routed to all major bearing points | Faedah Operasi: Ensures consistent component lubrication under all conditions; improves bearing life | Kesan ROI: Menghalang kegagalan galas bencana; reduces manual labor for daily maintenance
Structural Dynamics Engineering | Asas Teknikal: Analisis Unsur Terhingga (FEA) on primary support structures under full load and vibration | Faedah Operasi: Eliminates resonant fatigue cracking; memastikan integriti struktur jangka panjang | Kesan ROI: Avoids costly midlife structural reinforcements or emergency repairs
Optimized Conveyor Transfer Geometry | Asas Teknikal: CFD analysis of material trajectory to minimize impact angle at transfer points | Faedah Operasi: Dramatically reduces belt wear and dust generation at loading zones | Kesan ROI: Extends conveyor belt life; lowers dust suppression costs and associated fines

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Fabrikasi Standard Industri | Our Stone Quarry Crushing Plant Fabrication | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Pemasangan Di Tapak | 812 minggu (field welding/assembly) | 46 minggu (modular boltup) | ~50% pengurangan |
| Masa Min Antara Kegagalan (Critical Transfers) | ~6 months due to wear/plugging| ~18 months with optimized liners & geometri| ~200% increase |
| Penggunaan Tenaga setiap Tan Hancur| Garis dasar (100%)| Dianggarkan 8590% via optimized drive/motor sizing & reduced system friction| 1015% penambahbaikan |
| Fabrication Tolerances (Penjajaran) | +/ 1/4" typical field fitup| +/ 1/8" achieved in controlled factory setting| 50% greater precision |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 200 ke atas 1,500 tan per jam (Tph).
Keperluan kuasa: Plantwide demand from 500kW to 2500kW+, supplied via dedicated HV substation or multiple MV connections. All MCCs included.
Spesifikasi Bahan: Primary structure A36 carbon steel; Wear surfaces AR400/500 steel; Liners Manganese steel or composite alloys as specified.
Dimensi Fizikal: Fully modularized; maximum skid dimensions for transport are typically 12ft(W) x 60ft(L) x14ft(H).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C (4°F hingga 113°F). Dusttrenched electrical enclosures (Piawaian IP65).

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Cabaran: An existing operation needed to double throughput but had limited space for plant expansion and needed to maintain production during phased construction.
Penyelesaian: We fabricated a new tertiary crushing and screening tower on a single large skid alongside the existing plant. New conveyors were preassembled in sections.
Keputusan: The new module was installed over a scheduled 10day shutdown. Daya tampung meningkat sebanyak 95% with minimal disruption to ongoing production.

Pengeluar Agregat Batu Kapur

Cabaran: High silica content was causing severe abrasion in transfer chutes and screen decks, leading to weekly maintenance stops and inconsistent product screening efficiency.
Penyelesaian: We replaced standard chutes with computermodeled designs featuring ceramiclined impact zones and adjustable cascade lips. Polyurethane screen decks were customfitted.
Keputusan: Wear life increased from approximately one week per inspection cycle upto five weeks . Product consistency improved due to maintained screening accuracy.

7. PERTIMBANGAN KOMERSIL

Our fabrication services are structured around your project scope:

Peringkat Harga:
Tier I – Component Fabrication / Retrofits
Tier II – Complete Process Section Skids
Tier III – Turnkey Plant Design & Fabrikasi

Optional features include advanced dust suppression system integration, sistem pensampelan automatik, full PLC control panel fabrication,
and telemetryready sensor packages.

Service packages extend beyond installation support:
Foundation drawing packages certified by a Professional Engineer .
Multiyear scheduled inspection programs .
Onsite welding teams for final tieins .

Financing options can be discussed through our partners , including equipment leasing structures that treat the fabricated plant as capital asset .

Soalan Lazim

Q1 Are your fabricated plants compatible with our existing crushers screens?
A Yes we design interface modules specifically for this purpose . We require detailed OEM drawings connection points load data ensure seamless integration .

Q2 What typical lead time from design approval fabrication completion?
A For standard configuration lead times range between months depending complexity current shop workload . Critical path items like custom gearboxes may affect this schedule .

Q3 How does modular design impact future relocation site?
A Modular plants are inherently easier relocate . Each major skid can be disconnected transported reassembled new location significantly reducing cost time compared dismantling traditional welded structure .

Q4 Do you provide performance guarantees throughput product gradation?
A Yes based agreed upon feed material characteristics final plant design we provide guaranteed performance ranges capacity power consumption key product fractions .

Q5 What level detail required initial quotation?
A To provide meaningful budgetary quote we need target annual tonnage feed material analysis blast fragmentation size desired product specifications available footprint .

Q6 Who responsible structural engineering foundations?
A We provide complete foundation general arrangement drawings anchor bolt details stamped Professional Engineer client’s local geotechnical contractor responsible sitespecific soil analysis final pour .

Q7 Can you manage entire project including civil works electrical installation?
A As primary fabricator we typically partner with qualified regional contractors civil electrical work can provide single point coordination project management fee ensure all disciplines align schedule .