Targeting: Quarry Operations Managers, Plant Superintendents, Engineering Contractors

1. Addressing Your Core Operational Challenges in Stone Quarrying

Are escalating operational costs and unpredictable downtime eroding your quarry's profitability? The primary crushing stage sets the tone for your entire downstream process, and inefficiencies here compound rapidly. Common challenges include:

Unscheduled Downtime: Frequent liner changes, unexpected mechanical failures, and clogging from sticky or highclay feed material halt production. Industry averages indicate that every hour of crusher downtime can cost over $1,000 in lost production and labor.
High Maintenance Costs & Labor Intensity: Traditional jaw crushers require frequent, manual adjustments and liner replacements. The associated labor hours, parts inventory, and safety risks during maintenance directly impact your bottom line.
Inconsistent Product Gradation: Fluctuations in feed size or hardness lead to offspec product, causing recrushing cycles and reducing the yield of highvalue aggregate fractions.
Energy Inefficiency: Older crushing plants consume disproportionate power relative to throughput, with a significant portion of energy wasted as heat and vibration rather than effective size reduction.
Inflexibility to Feed Variation: A fixed crushing chamber struggles with seasonal changes in rock abrasiveness or moisture content, forcing operators to run at suboptimal settings.

Is your primary crushing plant a source of constant concern rather than a reliable foundation? A modern OEM stone quarry crushing plant is engineered to transform these pain points into controlled, predictable operations.

2. Product Overview: OEM Primary Stationary Crushing & Screening Plant

This solution is a complete, heavyduty stationary crushing plant engineered for the primary reduction of blasted quarry rock (limestone, granite, basalt) into consistent, coarse aggregate. It is designed as the cornerstone of a hightonnage aggregate production line.

Operational Workflow:
1. Feed & PreScreening: Runofquarry (ROQ) material is fed via dump truck into a robust vibrating grizzly feeder (VGF), which scalps out fine natural sand and small debris while directing oversize to the crusher.
2. Primary Size Reduction: The core jaw crusher utilizes compressive force to break large rocks (typically up to 1000mm) down to a manageable size (150250mm).
3. Material Transfer & Stockpiling: Crushed material is conveyed via heavyduty belt conveyors to either a primary stockpile for downstream processing or directly to secondary crushers.

Application Scope & Limitations:
Ideal For: Highvolume production of road base, subbase, and primary aggregate for concrete/asphalt; processing of medium to nonabrasive rock types.
Limitations: Not designed as a standalone finished product plant; secondary/tertiary stages are required for most spec aggregates. Extremely hard or highly abrasive ores (e.g., taconite) may require specific metallurgical configurations.

3. Core Features: Engineered for Reliability & ROI

Modular BoltTogether Structure | Technical Basis: Preengineered, heavyduty steel fabrication | Operational Benefit: Reduces field installation time by up to 30% versus welded designs, allows for future reconfiguration or relocation | ROI Impact: Lower capital installation costs and preserved longterm asset value.

Hydraulic Adjustment & Clearing | Technical Basis: Integrated hydraulic cylinders for toggle tension and chamber clearing | Operational Benefit: Enables remote adjustment of crusher settings in minutes and rapid clearing of stall events without manual intervention | ROI Impact: Minimizes downtime for routine adjustments by over 80% and enhances operator safety.

HeavyDuty Vibrating Grizzly Feeder (VGF) | Technical Basis: Highstrength deck bars with adjustable grizzly spacing | Operational Benefit: Effectively removes fines prior to crushing, reducing crusher wear and preventing bed packing | ROI Impact: Increases crusher capacity by optimizing feed and extends wear part life by 1525%.

PLCBased Automation System | Technical Basis: Centralized control with load management and fault diagnostics | Operational Benefit: Allows singleoperator control of the entire primary circuit, provides realtime performance data and predictive maintenance alerts | ROI Impact: Optimizes power consumption (typical savings of 510%) and reduces labor requirements per ton produced.

AbrasionResistant Material Specification | Technical Basis: Crusher liners fabricated from manganese steel alloy; wear plates on feed hopper and chutes | Operational Benefit: Withstands continuous impact abrasion from quarry rock, ensuring consistent geometry for product gradation | ROI Impact: Predictable wear life cycles enable scheduled maintenance planning, reducing emergency parts orders.

4. Competitive Advantages

| Performance Metric | Industry Standard Baseline | This OEM Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime | ~8590% (including adjustment stops) |> 94% achievable | +510% more production time |
| Liner Changeout Time (Jaw) | 812 hours manual labor| 50% faster |
| Energy Consumption (kWh/ton) Varies by rock type| Baseline = 100% |> Optimized drive & load management |> Reduction of 512% |
| Installation & Commissioning Time| Field welding & alignment| Preassembled modules bolted onsite |> Reduction of ~30% |

5. Technical Specifications

Design Capacity Range: 400 1,800 tonnes per hour (TPH), depending on model configuration and feed material.
Primary Crusher Type: Single Toggle Jaw Crusher.
Feed Opening Range: From 900mm x 600mm up to 1500mm x 1200mm.
Power Requirements: Total installed plant power typically between 200kW 450kW. Requires dedicated industrial power supply.
Key Material Specifications: Crusher frame – fabricated steel plate; Liners – ASMT A128 Manganese Steel; Conveyor idlers – CEMA C/D rated with sealed bearings.
Physical Dimensions (Typical): Footprint approximately 25m (L) x 8m (W). Height varies with feed hopper design.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system connections are standard.

6.Application Scenarios

Granite Quarry Expansion Project

Challenge: A large granite quarry needed to increase primary circuit throughput by 40% without expanding its operational footprint or significantly increasing crew size. The existing plant suffered from frequent clogging during wet conditions.
Solution: Implementation of a turnkey OEM crushing plant featuring an oversized VGF for effective fines removal and a jaw crusher with an aggressive stroke profile optimized for hard rock. The entire circuit was automated from a single control room.
Results: Throughput increased by 42%. Downtime due to weatherrelated clogging was eliminated. The operation achieved target output with no increase in direct operating labor.

Limestone Aggregate Producer

Challenge: High maintenance costs on an aging jaw crusher were unsustainable. Liner changes were excessively timeconsuming,and product gradation was inconsistent,due toworn mechanics.
Solution:SourcingandinstallinganewOEMprimarycrushingplantwithahydraulicadjustment systemandadvancedwearlinermonitoring.
Results:Linerchangetimewasreducedfrom10hoursto3.hours.Productgradationconsistencyimproved,directlyincreasingthe yieldofhighvalue57stoneby8%.Annualmaintenancepartscostswerereducedbyanestimated22%.

7.Commercial Considerations

PricingforacompleteOEMstationaryprimarycrushingplantisdeterminedbycapacityandconfiguration.Pleaseconsultforadetailedquotationbasedonyourspecificgeologyandproductiongoals.

PricingTiers:
• BasePlant(400700TPH):Includescrusher,VGF,basicdischargeconveyor,andmotorstarters.• StandardPlant(7001200TPH):AddsPLCautomation,dustsuppressionpackage,andheavierdutyconveyors.• PremiumPlant(1200+TPH):Includesadvancedconditionmonitoringsensors,totallyenclosedconveyors,andextendedwarrantycoverage.OptionalFeatures:
• Onboarddieselgeneratorforstandalonepower.• Magnetforferrousmetaltrampremoval.• Automaticlubricationsystems.• Rockbreakerboomystemforthefeedhopper.ServicePackages:
• Commissioning&OperatorTraining• PreventativeMaintenancePlans• GuaranteedWearPartsSupplyAgreementsFinancingOptions:
Equipmentfinancingandleasingoptionsareavailablethroughpartnerfinancialinstitutions,tailoredtocapitalexpenditurebudgets.FAQ:

Q1:Arewearpartsinterchangeablewithothermanufacturers'equipment?
A1:Crucialwearpartslikejawlinersaredesignedforspecificchamberkinematicsandarenotgenerallyinterchangeable.OEMpartsguaranteefitperformanceandlongevity.FielddatashowsusingOEMpartscanextendserviceintervalsbyupto15%.

Q2:Whatisthetypicalleadtimefromordertocommissioning?
A2:Fornstandardplantsconfigurationsleadtimesrangefrom20to32weeksdependingoncomplexityandcurrentglobaldemand.Modulardesignsacceleratesitecommissioningtounderthreeweeks.Q3:Canyourplantintegratewithourexistingsecondarycircuitandscreens?
A3 YesIntegrationisakeyconsiderationOurengineeringteamwillreviewyourcurrentlayoutconveyorheightsandcontrolsystemstoensurecompatibleseamlessmaterialhandling.Q4Howdoesyoursolutionaddressnoiseandemissionsdustcontrol?
A4TheplantisdesignedwithintegrateddustsuppressionnozzleconnectionsandenclosedtransferpointsAcousticenclosuresforthecrusherandmotorsareavailableasoptions tomeetlocalregulations.Q5Whattrainingisdrovidedforouroperatorsandmaintenancestaff?
A5Comprehensiveonsitetrainingisincludedcoveringnormaloperationemergencyproceduresroutine maintenanceandsafetyprotocolsDocumentationincludesdetailedmanualsandelectricalschematics.Q6Doyouofferperformanceguarantees?
A6YesWeprovideguaranteedthroughputcapacitybasedonspecifiedfeedmaterialaswellasmechanicalavailabilitywhentiedtoarecommendedmaintenanceplan.Q7Whatisthewarrantystructure?
A7Thestandardwarrantycoverdefectsinmaterialsworkmanshipformajorcomponentscrusherstructuredrivesforaperiodof12monthsfromcommissioningExtendedwarrantiesareavailable