1. PAINPOINT DRIVEN OPENING

Are unpredictable breakdowns and inconsistent output crippling your aggregate production schedule? For plant managers and engineering contractors, a suboptimal crushing plant directly impacts the bottom line through excessive downtime, high perton operating costs, and missed project deadlines. Common challenges include:

Unscheduled Downtime: Component failures in critical crushers or feeders can halt operations for days, costing thousands in lost revenue and labor.
High Maintenance Costs: Poorly designed plants with difficult access points increase routine service time by 3040%, while nonstandard parts inflate inventory and repair expenses.
Inconsistent Product Gradation: Fluctuations in final product size can lead to material rejection, requiring recrushing and wasting energy.
Rapid Wear Part Degradation: Improper chamber design or material flow accelerates wear on liners and blow bars, significantly increasing consumable costs per ton.
Inefficient Layout & Flow: Bottlenecks in material transfer between screening and crushing stages limit overall plant capacity, forcing you to run equipment below its potential.

Is your current setup a constant source of operational friction? What if your crushing plant could be a reliable, predictable asset engineered for maximum uptime and controlled costperton?

2. PRODUCT OVERVIEW: OEM Stone Crusher Plant

An OEM Stone Crusher Plant is a fully integrated, stationary or semimobile processing system designed for the primary, secondary, and tertiary reduction of quarried rock, river gravel, and recycled concrete into specified aggregate sizes. Engineered as a cohesive unit from a single Original Equipment Manufacturer (OEM), it ensures compatibility and optimized performance across all components.

Operational Workflow:
1. Primary Feeding & Crushing: Runofquarry material is consistently fed via a vibratory grizzly feeder to a primary jaw crusher for initial size reduction.
2. Secondary Processing & Screening: Crushed material is conveyed to a secondary cone or impact crusher. A closedcircuit system with a sizing screen separates finished product from oversize material for recirculation.
3. Final Sorting & Stockpiling: Correctly sized aggregate is sorted via screens into final product fractions (e.g., 05mm, 520mm) and conveyed to designated stockpiles.

Application Scope: Ideal for highvolume production of construction aggregates (road base, concrete stone, asphalt chips) in quarrying, mining, and large infrastructure projects.

Limitations: Not suitable for portable/mobile contract crushing requiring frequent relocation. Maximum feed size and hardness are constrained by the modelspecific design of the primary crusher.

3. CORE FEATURES

Unified OEM Control System | Technical Basis: Centralized PLC with integrated motor management | Operational Benefit: Your operators monitor and control the entire plant flow from a single panel, simplifying startup/shutdown sequences and fault diagnosis | ROI Impact: Reduces system commissioning time by up to 25% and minimizes operator errorrelated stoppages
Optimized Chassis & Walkways | Technical Basis: Structural analysis for load distribution and safe personnel access | Operational Benefit: Provides maintenance crews with 360degree safe access to all lubrication points, wear part inspection panels, and conveyor drives | ROI Impact: Cuts scheduled maintenance duration by an average of 35%, enhancing planned availability
HeavyDuty Vibratory Feeder with Grizzly Section | Technical Basis: Controlled vibration frequency/amplitude paired with rugged grizzly bars | Operational Benefit: Ensures steady, regulated feed to the primary crusher while scalping out fine natural material to bypass unnecessary crushing | ROI Impact: Increases primary crusher efficiency by reducing cavity wear from fines and can boost throughput by 1015%
ClosedCircuit Crushing & Screening Loop | Technical Basis: Recirculating conveyor returning oversize material from screen decks back to the secondary crusher | Operational Benefit: Guarantees precise control over final product size specification without manual intervention | ROI Impact: Eliminates product waste due to offspec material; field data shows a 98% consistency rate in gradation
AbrasionResistant Material Conveying | Technical Basis: Chevron pattern belts with impact beds at loading points and sealed bearings | Operational Benefit: Minimizes spillage and belt wear from sharp aggregate edges at transfer points | ROI Impact: Extends conveyor belt service life by approximately 20%, lowering longterm component replacement costs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (NonOEM/Modular) | OEM Stone Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Planned Availability | ~85% (mixedvendor integration issues) | 94%+ (engineered compatibility) | >10% Increase |
| Wear Part Life (Liners)| Variable; often nonoptimized geometry| Consistent lifecycle; chamberdesigned parts| Up to 25% Longer Life |
| Energy Consumption per Ton| Higher due to potential flow restrictions| Optimized motor sizing & material flow path| Documented 812% Reduction |
| Mean Time To Repair (MTTR)| Extended due to part sourcing complexity| Standardized parts inventory & clear manuals| Estimated 30% Faster Repair |
| Footprint Efficiency| Often larger due to nonintegrated layout| Compact design with preplanned flow logic| Up to 15% Smaller Footprint |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 TPH to 600+ TPH final product output.
Power Requirements: Total connected load typically between 350 kW 800 kW depending on configuration; requires dedicated industrial power supply (400V/50Hz or 480V/60Hz standard).
Material Specifications: Engineered for compressive strength up to 350 MPa. Primary crusher jaws and secondary mantles/liners constructed from Mnsteel alloy (18%22% Manganese).
Physical Dimensions (Example for 250 TPH Plant): Approximate length: 35m; width: 18m; height (max): 12m. Foundation requirements provided in detailed civil engineering drawings.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system included as standard; sound enclosures available as an option to meet local regulations.

6. APPLICATION SCENARIOS

Granite Quarry Operation | Challenge: A granite quarry faced excessive downtime from premature failure of cone crusher bearings in their aging multibrand circuit, causing unpredictable output delays for major infrastructure contracts. | Solution: Implementation of a complete OEM stone crusher plant featuring a primary jaw crusher matched with two secondary cone crushers on a shared heavyduty chassis with centralized lubrication. All bearings were oversized per OEM specification.| Results: Bearing replacement intervals extended from 6 months to over 24 months. Plant availability increased from 82% to 93%, enabling the consistent fulfillment of monthly tonnage targets.

Urban Recycling Center producing RCA (Recycled Concrete Aggregate) Challenge Abrasive concrete debris combined with intermittent tramp metal caused rapid wear on impactor blow bars and frequent belt damage at transfer points in their existing setup.| Solution Installation of an OEM stone crusher plant configured with an impact crusher featuring hydraulic opening for safer blow bar changes magnetic separator on feed conveyor heavyduty rubber lagged pulleys.| Results Blow bar life improved by reducing uncrushable metal contact Belt puncture incidents decreased by over The resulting RCA met strict DOT specifications reliably creating new revenue stream

Commercial Considerations

Pricing is structured around plant capacity core configuration:
Tier Basic Plant includes primary secondary crushing single screen deck essential conveyors Tier Advanced Plant adds tertiary crusher multiple screen decks automated dust control central grease system Optional Features include onboard power generation advanced automation SCADA connectivity extended walkway covers sound attenuation modules Service Packages are offered as annual comprehensive plans covering scheduled inspections parts discounts priority support Financing Options include capital lease operating lease or loan structures through partner institutions typically ranging terms facilitate cash flow management

FAQ

What defines an true The term signifies that entire system including mechanical electrical controls is designed supplied warranted by single manufacturer ensuring component compatibility performance guarantees unlike assembled multi vendor setup Is compatible with my existing conveyors stackers While possible integration not recommended as optimal performance calibrated specific interaction between all subsystems retrofitting often diminishes overall efficiency How quickly can operational after delivery Delivery installation timeline varies capacity complexity typical turnkey project involves weeks site preparation foundation work followed weeks mechanical erection electrical commissioning supervised team What typical payback period investment Based historical data operations achieving targeted throughput well maintained plants see return investment through reduced operating costs increased production within year timeframe What happens need spare part years time As committed manufacturer maintain full technical drawings bill materials critical components ensuring part availability lifespan minimum years post production