1. PAINPOINT DRIVEN OPENING

Managing a stone quarry crushing plant presents persistent operational challenges that directly impact your bottom line. Are you facing:
Excessive Downtime: Unplanned stoppages for liner changes, blockages, or mechanical failures can cost over $1,500 per hour in lost production and labor.
Inconsistent Final Product: Fluctuations in aggregate size and shape lead to product rejection, reduced selling price, and wasted raw material.
Rising Operational Costs: Spiking energy consumption from inefficient crushing circuits and the high frequency of wear part replacement erode profit margins.
Bottlenecks in Material Flow: Mismatched capacity between primary, secondary, and tertiary stages limits total plant throughput, leaving potential revenue untapped.
Compliance & Safety Risks: Dust emission control failures and manual clearing of jammed crushers create environmental liabilities and hazardous work conditions.

The central question for plant managers is: how can you achieve higher throughput with greater reliability while controlling the total cost of ownership? The answer lies in a fundamentally optimized ODM stone quarry crushing plant.

2. PRODUCT OVERVIEW

This ODM (Original Design Manufacturer) stationary crushing plant is engineered as a complete, synchronized system for highvolume aggregate production from hard rock formations like granite, basalt, and limestone.

Operational Workflow:
1. Primary Size Reduction: Dump trucks feed shot rock into a heavyduty jaw crusher for initial compression breaking.
2. Secondary Crushing & Screening: The primary output is conveyed to a cone crusher for further reduction. A vibrating screen separates material to specification; oversize is recirculated.
3. Tertiary/Quaternary Shaping: For highgrade chips and sand, material may be routed to additional vertical shaft impact (VSI) crushers for precise shaping and fines generation.
4. Material Sorting & Stockpiling: Final screened aggregates are conveyed to designated stockpiles via radial stackers.

Application Scope & Limitations:
Scope: Ideal for medium to largescale quarry operations requiring consistent output of 200800 TPH of crushed stone aggregates (e.g., base course, concrete aggregate, asphalt chips).
Limitations: Not designed for mobile or semimobile applications. Feed rock hardness must align with crusher chamber design specifications; extremely abrasive materials will accelerate wear part consumption.

3. CORE FEATURES

Modular Plant Design | Technical Basis: Preengineered, skidmounted modules with standardized interfaces | Operational Benefit: Reduces site installation time by up to 40% versus traditional fieldbuilt plants | ROI Impact: Faster commissioning accelerates revenue generation; modularity allows for future circuit reconfiguration.

Intelligent Process Control System | Technical Basis: Centralized PLC with loadmanagement algorithms and remote monitoring capability | Operational Benefit: Automatically regulates feeder rates to prevent crusher overload and optimizes power draw across the circuit | ROI Impact: Field data shows a 712% reduction in specific energy consumption (kWh/ton).

HeavyDuty Crusher Configuration | Technical Basis: Jaw crusher with bolted (nonwelded) frame and cone crusher with hydraulic setting adjustment & clearing | Operational Benefit: Provides exceptional durability for hard rock and allows operators to adjust product size or clear a cavity jam in minutes without stopping the feed | ROI Impact: Minimizes downtime events; hydraulic tramp release protects major components from catastrophic damage.

Advanced Dust Suppression Integration | Technical Basis: Strategically placed spray nozzles with solenoid valves tied to conveyor load sensors | Operational Benefit: Suppresses dust at transfer points only when material is moving, using up to 30% less water | ROI Impact: Ensures consistent compliance with environmental regulations while reducing water consumption and slurry handling costs.

Wear Part Optimization | Technical Basis: CADdesigned manganese steel castings with guaranteed fitment across liner life cycles | Operational Benefit: Your maintenance team achieves predictable changeout schedules with perfectly fitting parts that maintain crushing chamber geometry | ROI Impact: Consistent chamber geometry yields optimal product shape and up to 15% longer liner life compared to nonOEM alternatives.

Centralized Greasing & Lube System | Technical Basis: Automated singlepoint lubrication system for all major crusher bearings | Operational Benefit: Eliminates manual greasing errors and ensures critical bearings receive correct lubrication during operation | ROI Impact: Extends bearing service life by an average of 20%, preventing costly unscheduled repairs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | This ODM Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Plant Availability (Scheduled Runtime) | 8590% (incl. maintenance) | 9295%+ (incl. maintenance)| +58% |
| Specific Energy Consumption (kWh per ton) Varies by rock type. Baseline set at industry average from published studies.| ~0.8 1.2 kWh/tonne (for hard rock circuit)| ~0.7 1.05 kWh/tonne| Up to 12% reduction |
| Wear Part Cost per Ton (Cone Crusher Liner Life)| Based on abrasive granite; ~$0.25 $0.35/ton| Optimized chamber & alloy extends life; ~$0.21 $0.30/ton| Up to 15% savings |
| OnSite Installation & Commissioning Time| 812 weeks for a 500 TPH plant| Modular design reduces build time; ~58 weeks| Up to 40% faster |

5.TECHNICAL SPECIFICATIONS

Design Throughput Capacity: Configurable from 200 to over 800 metric tons per hour (TPH), depending on feed material hardness (<250 MPa recommended) and final product size requirements.
Power Requirements: Total connected load typically ranges from 450 kW to 1.2 MW for a complete plant circuit, dependent on configuration.
Key Material Specifications:
Primary Crusher Feed Opening Range Options: From approx..900mm x600mm up to1500mm x1200mm
Conveyor Belting Minimum Rating EP800/4
Structural Steel Frame Fabricated from S355JR grade steel
Wear Parts Premium manganese steel alloys
Physical Dimensions (Example Configuration):
Primary Module w/Jaw Crusher (~500 TPH): L15m x W4m x H5m
Secondary/Tertiary Module w/Cone & Screens (~500 TPH): L20m x W6m x H8m
Control Cabin Standard ISO Container dimensions
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system maintains emissions below local regulatory thresholds (<50 mg/Nm³ typical).

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A quarry in Southeast Asia needed to increase production by60%to fulfill a major infrastructure contract but had limited space for plant expansionand facedhighly abrasive feed material.
Solution Implementation ofa compactODMcrushingplant featuringa highcapacity jawcrusherandacone crusherspecifically configuredforabrasive rockwith enhancedwearpart alloys.Thelayoutwasoptimizedfor theexisting site footprint.
Results Theplant achieveda sustained throughputof520TPHofhighquality roadbaseandconcreteaggregate.Availabilityremainedat93%duringthefirstyear,andwearpartcostsper tonwere15%belowthepreviousoperation’sbenchmarkenablingthecontracttobe fulfilledon schedule

Limestone Aggregate Plant Modernization

Challenge An aging singlestage impactor plant produced excessive fines (5mm)and sufferedfromfrequentunplannedstoppagesdue tocage blockagesleadingtoproduct mix imbalancesandhighmaintenancecosts
Solution ReplacementwithatwostageODMplant featuringaprimaryjawcrushera secondarycone crusherforcontrolledreductionandahighefficiency tripledeckscreenforprecisefines separationThesystemincludedanautomatedPLCforloadmanagement
Results Finesproductionwasreducedby22%increasingthe yieldofvaluablecoarseaggregatesPlantthroughputincreasedby35%downtimeforblockageswasvirtuallyeliminatedandenergyconsumptionper tonfellby9%

7. COMMERCIAL CONSIDERATIONS

PricingfortheODMstonequarrycrushingplantisstructuredontheconfiguredsolutionwithcleartiersbasedoncapacityandcomplexity

EquipmentPricingTiers
TierI(200350TPHBasicCircuitJawCrusherScreenConveyorsControlSystem)
TierII(350600TPHEnhancedCircuitJawConeCrushersMultiStageScreeningDustSuppression)
TierIII(600+TPHAdvancedCircuitMultipleCrushingStationsAdvancedAutomationFullDustCollection)

OptionalFeaturesInclude
AutomatedWearPartMonitoringSystems
SoundEnclosureCanopies
OnboardPowerGenerationPackages
AdvancedPredictiveMaintenanceSensorKits

ServicePackagesAcomprehensiveselectionisavailableincluding
StandardWarranty(12monthsonmajorcomponents)
ExtendedProtectionPlans(upto36months)
AnnualInspection&OptimizationContracts
OnSiteTechnicalTrainingforOperators&MaintenanceCrews

FinancingOptionsFlexiblecommercialtermscanbesupportedincludingoperatingleasestructurescapitalequipmentloansandleasetoownprogramstospreadthecapitalinvestmentovertime

8. FAQ

Whatisfitmentlikeformyexistingquarryinfrastructure?
ThemodulardesignallowsforsignificantlayoutflexibilityOurpresalesengineeringteamconductsa sitesurveytoensureconveyoranglesfeedhopperelevationsandstockpilelocationsareintegratedwithyourexistinghaulroadsandsurfacelogistics

Howdoesthisplantspecificallyaddressoperationalcosts?
Itattacks costsacross threeareasFirstthroughintelligentcontrolthatlowersenergyuseSecondthroughdurablewearpartsoptimizedchamberdesignthatlowerscostpertonThirdbymaximizingavailabilitythroughreliabledesignwhichdirectlyprotectsyourrevenue stream

Whatisthetypicalimplementationtimelinefromordertooperation?
Followingdetailedengineeringleadtimeformanufacturingis1620weeksModularconstructionallowsonsiteinstallationandcommissioningin58weeksdependingonfoundationpreparednessTotalprojecttimetypicallyrangesfrom610months

Arewearpartsproprietaryorcanwesourcealternatives?
ThecrushingchambersaredesignedforspecificOEMlinerstodelivertheadvertisedperformanceandsafetyWhiletechnicallycompatiblewithsomeaftermarketpartsusingnonOEMlinersoftenresultsinreducedthroughputpoorerproductshapeandincreasedriskofdamagetoothercomponentsvoidingwarrantiesWeoffercompetitiveguaranteedfitlinerpackagestoensurepredictableoperatingcost

Whattrainingandsupportisprovided?
WeincludecomprehensiveonsiteoperatorandmaintenancetrainingduringcommissioningThisissupplementedbydetailedmanualsandschematicaccessviaaportalAdditionallyourservicecontractsincluderegularhealthcheckvisits