1. PAINPOINT DRIVEN OPENING

Are you managing a highvolume aggregate operation and facing persistent bottlenecks that erode profitability? For plant managers and engineering contractors, a 250300 tph crushing plant is the backbone of production, yet common operational challenges persist. These include inconsistent feed causing crusher chokeups and unplanned downtime; excessive wear part costs from suboptimal crushing chambers; high energy consumption per ton processed; difficulty meeting strict aggregate gradation specifications; and logistical complexities in plant setup and relocation. The cumulative effect is measurable: every hour of unscheduled downtime can mean over 250 tons of lost production, directly impacting project timelines and contract fulfillment. How do you achieve reliable, hightonnage output while controlling operational costs and maintaining product quality? The solution lies in a purposeengineered Premium 250300tph Stone Crushing Plant designed from the ground up for maximum uptime and efficiency.

2. PRODUCT OVERVIEW

This solution is a complete, stationary or semimobile 250300tph Stone Crushing Plant, engineered as a turnkey system for largescale quarrying, mining, and major infrastructure projects. The plant is configured for primary, secondary, and tertiary crushing stages to produce precisely graded aggregates (05mm, 510mm, 1020mm, 2031.5mm, etc.). Its operational workflow is streamlined: 1) Primary jaw crusher reduces large feed (≤750mm) to ≤200mm; 2) Material is screened and conveyed to secondary cone crushers for further reduction; 3) Final shaping and cubicity are achieved in tertiary crushers (cone or impact); 4) Multipledeck screens precisely separate final products; 5) Integrated dust suppression maintains environmental compliance. This plant is suited for processing hard rock (granite, basalt) and abrasive materials but requires professional engineering for highly sticky or claybound feeds.

3. CORE FEATURES

Intelligent Crushing Chamber Design | Technical Basis: CADoptimized geometry & kinematics | Operational Benefit: Maximizes interparticle crushing, reduces slabby product, ensures consistent cavity wear | ROI Impact: Up to 15% longer wear part life, reduced changeout frequency & labor costs
HeavyDuty Vibrating Feeder with PreScreening | Technical Basis: Grizzly section removes fines before primary crusher | Operational Benefit: Eliminates primary crusher chokeups, increases effective capacity | ROI Impact: Prevents costly downtime events & improves overall system throughput by 812%
Centralized PLC Automation System | Technical Basis: Programmable Logic Controller with touchscreen HMI | Operational Benefit: Enables singlepoint start/stop sequence monitoring, realtime alarm diagnostics, & remote performance tracking | ROI Impact: Reduces manpower requirements for operation & enables proactive maintenance scheduling
HighEfficiency Cone Crushers with Hydroset Control | Technical Basis: Hydraulic adjustment & overload protection system | Operational Benefit: Allows onthefly CSS adjustment for product gradation changes & automatic tramp iron release | ROI Impact: Minimizes noncrushable material damage events & maintains precise product specs without stopping
Modular Skid/Frame Construction | Technical Basis: Preassembled modules with integrated walkways & maintenance platforms | Operational Benefit: Significantly reduces site installation time & improves worker safety during maintenance | ROI Impact: Cuts civil works and erection costs by an estimated 30%, accelerating timetoproduction
Advanced Dust Suppression System | Technical Basis: Strategically placed nozzles with solenoid valve control at transfer points | Operational Benefit: Effectively controls airborne particulate without oversaturating material | ROI Impact: Ensures continuous compliance with environmental regulations, avoiding fines and work stoppages

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (250300tph Plant) | Premium OEM Solution (This Plant) | Advantage (% Improvement) |
| : | : | : | : |
| Overall Availability | ~8588% (planned + unplanned downtime) | 9294% (field data verified) | +5% to +7% more productive hours |
| Energy Consumption per Ton| ~1.8 2.1 kWh/t for hard rock| 1.6 1.75 kWh/t (system optimized)| ~1015% lower operating cost |
| Wear Cost per Ton (Primary)| $0.08 $0.12 / t| $0.065 $0.095 / t| Up to 20% reduction possible |
| Average Setup Time| 46 weeks for full commissioning| 2.5 4 weeks (modular design)| ~30% faster deployment |
| Final Product Cubicity Index| Varies widely; often 85% cubicity (tertiary stage)| Superior product value for asphalt/concrete |

5. TECHNICAL SPECIFICATIONS

Designed Capacity: Steadystate output of 250 – 300 metric tons per hour of finished aggregate.
Feed Size: Maximum lump size ≤750mm.
Primary Crusher: Heavyduty jaw crusher (e.g., PE900x1200), power rating 132160 kW.
Secondary/Tertiary Crushers: Multicylinder hydraulic cone crushers (e.g., HPC315), total installed power up to 400 kW.
Screening: Multideck vibrating screens (e.g., 3YK3072), total area ≥21m².
Conveyors: Belt width B1000B1200 mm, with impact beds at loading points.
Electrical System: Total connected power ~800 – 1000 kVA; voltage customizable to regional standards (380V/50Hz, 460V/60Hz).
Key Material Specifications: Highstrength steel frames; Manganese steel wear liners (14%18%); Imported heavyduty bearings & seals.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate options.

6. APPLICATION SCENARIOS

Highway Construction Consortium Project

Challenge: Required consistent supply of >280tph of highspecification aggregates (multiple grades) for a toll road project under tight schedule penalties.
Solution: Implementation of a turnkey Premium OEM Stone Crushing Plant with tertiary shaping stage.
Results: Achieved average output of 290tph at >90% availability over 18 months; met all gradation and flakiness index specifications without recrushing; project completed ahead of schedule.

Large Granite Quarry Expansion

Challenge: Existing aging plant could not reliably exceed 220tph,causing backlog,and had prohibitive maintenance costs.
Solution: Installation of this new Premium OEM Stone Crushing Plant as a parallel production line,focusing on energy efficiency.
Results: New line operates at 295tph with 18% lower energy cost per ton compared to old line;modular design allowed installation during ongoing quarry operations.

7.COMMERCIAL CONSIDERATIONS

Pricing for a complete Premium OEM Stone Crushing Plant is tiered based on configuration:
• Base Configuration(primary+secondary+screening):Competitive capital investment focused on core reduction.
• Premium Configuration(+tertiary shaping+advanced automation):Higher initial investment delivering superior product shape&operational control&lower lifetime cost.
• Optional Features:Dust encapsulation covers,mobile trackmounted primary unit,diesel generator backup package,specific wear liner alloys.
• Service Packages:Tiered offerings from basic commissioning&training to comprehensive annual maintenance contracts(AMCs)with guaranteed parts availability&performance audits.
• Financing Options:The OEM factory can facilitate equipment financing or leasing structures through partner institutions,tailored to project cash flow requirements.

8.FAQ

Q:What if my feed material hardness changes after purchase?
A:The hydroset adjustment on cone crushers allows you to modify the closedside setting(CSS)and potentially the crushing chamber profile via liners to accommodate varying hardness while protecting the machine.

Q:What level of operator training is provided?
A.Comprehensive training is included covering normal operation,troubleshooting,and safety procedures.We provide both onsite training during commissioningand classroom sessions at our facility.

Q.How does this plant handle electrical supply fluctuations common in remote sites?
A.The PLC system includes under/overvoltage protection.Critical components use premium drives with builtin protection.For extreme conditions,a dedicated generator backup package is recommended as an option.

Q.What are the typical lead times from order to commissioning?
A.For standard configurations lead time ranges from 16to24weeks exworks.Detailed project planning including foundation drawingsis provided immediately postorder to parallelize site preparation

Q.Are spare parts guaranteed to be available longterm?
A.As an OEM factory we maintaina perpetual inventoryof critical wear&mechanical partsfor all machinery we produce typically guaranteeinga minimumof10years parts support

Q.Can the plant be relocated if needed?
A.The modular skidded designis specifically engineeredfor relocation.Conveyor sectionscrusher modulesand screen towerscan be disassembledinto transportable units significantly reducing redeployment costs versus fixed foundations