1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your iron ore processing margins? For plant managers and engineering contractors, the primary crushing stage is a critical bottleneck with direct consequences for your entire operation. Common challenges include:

Excessive Downtime for Maintenance: Frequent liner changes and unplanned repairs on your primary crusher halt the entire feed system, costing thousands per hour in lost production.
High Wear Part Costs & Consumption: Abrasive iron ore rapidly degrades crusher components, leading to unsustainable spending on manganese steel and arduous, laborintensive replacement cycles.
Inconsistent Feed Size Reduction: Fluctuations in feed size or hardness can cause choke feeding or cavity flooding, reducing throughput and creating downstream processing instability.
Rigid Plant Layout Constraints: Fixed primary crushing stations lack mobility, complicating mine plan progression and requiring costly overburden removal or lengthy rehandling.

Is your current solution equipped to handle increasingly hard and abrasive ore bodies while maintaining costpertonne targets? A strategically selected private label iron ore crushing plant provides a tailored answer to these systemic challenges.

2. PRODUCT OVERVIEW

A private label iron ore crushing plant is a heavyduty, semistationary or modular primary crushing system engineered specifically for the highvolume, highabrasion reduction of runofmine (ROM) iron ore. These plants are manufactured under contract to meet precise operational specifications and are branded for the distributor or large contractor.

Operational Workflow:
1. ROM Receiving & PreScreening: Direct dump from haul trucks onto a robust grizzly or scalping screen to bypass subfines material.
2. Primary Size Reduction: Oversize material is conveyed to a highcapacity jaw crusher or gyratory crusher for initial reduction to a manageable transport size (typically <250mm).
3. Primary Stockpiling: Crushed product is conveyed to a live stockpile, providing crucial surge capacity for downstream processing circuits.

Application Scope: Ideal for greenfield site development, dedicated processing lines for specific ore types, or as a supplemental primary station for existing operations. Best suited for operations with a defined mine life and consistent feed characteristics.

Limitations: Not designed as portable trackmounted units for frequent relocation. Maximum efficiency is achieved with proper feed control and consistent ore geology. Requires foundational civil works and integration engineering.

3. CORE FEATURES

HeavyDuty Crusher Frame | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Eliminates frame fatigue cracking under shock loads from uncrushable material | ROI Impact: Reduces risk of catastrophic structural failure, extending asset service life beyond 10+ years

AbrasionResistant Material Flow System | Technical Basis: Hardox® or equivalent wear steel in hoppers, skirts, and chutes; ceramic lagging on critical pulley faces | Operational Benefit: Dramatically reduces material adherence and wearthrough in transfer points | ROI Impact: Cuts maintenance welding/replacement frequency by up to 60%, lowering direct labor and parts costs

PLCBased Automated Control & Monitoring | Technical Basis: Centralized programmable logic controller with loadsharing algorithms and remote telemetry capability | Operational Benefit: Optimizes crusher power draw, prevents choke events, and provides realtime operational data | ROI Impact: Improves throughput consistency by an estimated 812% while enabling predictive maintenance scheduling

Modular Conveyor & Walkway Design | Technical Basis: Bolttogether sections with standardized dimensions | Operational Benefit: Enables faster installation onsite and allows future reconfiguration as mine layout evolves | ROI Impact: Reduces initial construction time/cost by approximately 1520% versus fully welded structures

Centralized Lube & Hydraulic System | Technical Basis: Singlepoint lubrication lines to all major bearings; dedicated hydraulic power unit for crusher adjustment/clearing | Operational Benefit: Simplifies routine servicing intervals and enhances operator safety during maintenance tasks | ROI Impact: Decreases scheduled maintenance downtime windows by an average of 30%

Integrated Dust Suppression Manifold | Technical Basis: Nozzle system plumbed into primary transfer points, tied to conveyor operation sensors | Operational Benefit: Actively controls dust at source, improving site visibility and compliance with environmental regulations | ROI Impact: Mitigates risk of regulatory fines and reduces cleanup costs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Plant) | Private Label Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Mn Steel)| 450,000 550,000 tonnes| 600,000 750,000 tonnes| +25% to +35% |
| Mean Time Between Failure (MTBF)| ~720 hours| ~1,100 hours| +53% |
| Tonnage Throughput Consistency| ±15% variance from target| ±7% variance from target| >50% improvement in stability |
| OnSite Installation Duration| 1216 weeks| 810 weeks| ~33% reduction |
| Specific Power Consumption| Benchmark = 100%| Achieves 9295% of benchmark| 58% improvement in energy efficiency |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Configurable from 1,200 to over 3,500 tonnes per hour (TPH), based on crusher selection.
Primary Crusher Options: Single Toggle Jaw Crusher (1.2m x 1.5m up to 1.6m x 2.0m) or Primary Gyratory Crusher (4265 range).
Power Requirements: Total installed power typically between 450kW 900kW depending on configuration; supplied at either 6.6kV or medium voltage.
Material Specifications: Primary structure ASTM A36 carbon steel; wear surfaces Hardox® 450/500; crusher liners ASTM A128 Manganese Steel.
Physical Dimensions (Typical): Footprint approximately 25m L x 18m W x 15m H (excluding feed ramp and discharge stockpile).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust protection rating of IP65 for electrical enclosures.

6. APPLICATION SCENARIOS

Direct Feed Hematite Operation

Challenge: An existing hematite operation used a legacy crusher located far from the new pit face, requiring doublehandling by loaders and incurring high hourly equipment rental costs.
Solution: Implementation of a private label iron ore crushing plant with a deeppit receiving hopper adjacent to the new pit rim.
Results: Elimination of loader rehandling reduced operating costs by approximately $0.85 per tonne hauled. The plant achieved design throughput within two weeks of commissioning.

Magnetite Concentrator Expansion

Challenge: A magnetite concentrator needed to increase primary crushed tonnage by over onethird but had limited space within the existing fixed infrastructure footprint.
Solution: Deployment of a modular private label crushing plant designed with vertical stacking conveyors to fit the constrained site layout.
Results:The modular design reduced civil works by an estimated $300k USD compared to traditional construction.The expansion was completed during a planned twoweek shutdown with no further production delays.

HighAbrasion Banded Iron Formation

Challenge:A new BIF deposit exhibited higherthanaverage abrasiveness index values,causing premature failure of conveyor belts,crusher liners,and chutes in test runs using standard equipment.
Solution:A bespoke private label solution featuring enhanced wear packages,a slowerspeed jaw crusher configuration,and specialized impact beds on all transfer points.
Results:Liner life improved by over onethird against initial projections.Conveyor belt replacement intervals extended from six months back toward standard ninemonth cycles,saving $120k annually in belt costs alone.

7.COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around core crusher selection:

Tier I(HighCapacity Jaw Crusher Based):For midrange tonnage requirements.Capital cost range:$2M$4M USD depending on options.
Tier II(Primary Gyratory Crusher Based):For maximum throughput (>2，500 TPH)and hard，abrasive ores.Capital cost range:$4M$7M USD depending on options.

Optional Features:
OnBoard Power Generation Package
Advanced Particle Size Monitoring(PSM)System
Automated Greasing Systems
Full Perimeter Dust Containment Skirting

Service Packages:
Commissioning & Operator Training(Standard)
Annual Inspection & Parts Kitting Agreement
FullService Maintenance Contract with guaranteed uptime SLA

Financing Options:
Available through partner financial institutions including operating lease structures，capital leasetoown plans，or projectbased financing tailored for mining developments.This allows preservation of capital while securing critical production infrastructure.

8.FAQ

Q:What level of customization is possible with a private label plant versus an OEM standard model?
A：Significant customization is core to the value proposition.You can specify crusher manufacturer，drive motor suppliers，conveyor belt grade，control system brand（e.g.,Siemens，AllenBradley），and structural details like access stair placement.This ensures compatibility with your existing spares inventory和maintenance practices。

Q：How does this solution integrate with my existing secondary crushing circuit和downstream processing？
A：The plants are engineered based on your required final product size（typically 250mm）for optimal secondary circuit feed.Design parameters include discharge height，conveyor speed和transfer point geometryto match your existing receiving hoppers或stockpile conveyors seamlessly。

Q：What are the lead times from order placementto commissioning？
A：Lead times vary but typically range from32to48weeksfor complete plants.This includes detailed engineering，manufacturing，shop assembly testing，dismantlementfor shipment和reassemblyon your site。Expedited options may be available。

Q：Can you provide performance guarantees？
A：Yes。Performance guaranteesfor throughput capacity based on agreed feed material specificationsand product sizeare standardin contracts。Wear rate guaranteesfor key components like linerscan also be structuredbased on agreed abrasiveness indices。

Q：Who holds responsibilityfor equipment warranties？
A：The private label dealer holds ultimate responsibilityfor warranty administration。Components are coveredby their original manufacturer's warranties（e.g.,crusher,bearings,motors），while structuraland assembly workmanshipis warranted directlyby the fabricator under our singlepoint accountability。

Q：What trainingand documentationare provided？
A：Comprehensive documentation包括asbuilt drawings,P&IDs，electrical schematics，parts manuals和lubrication schedules。Onsite trainingfor operationsand maintenance crews is conductedduring commissioningwith both classroomand handson modules。

Q：Are these plants suitablefor remote locationswith limited service support？
A：Yes。They are designedwith serviceabilityas apriority。Common component standardization,easy access platformsand designedin service tool clearances reduce required skill levelsfor routine tasks。Remote monitoring capabilityallows our support teamsto assistwith diagnosticsoffsite。