1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your project margins? For plant managers and engineering contractors, the crushing and screening circuit is often the source of critical bottlenecks. Common challenges include:
Unscheduled Downtime: Component failures in harsh environments lead to production halts, costing thousands per hour in lost throughput and labor.
Inconsistent Product Gradation: Outdated or inefficient screening leads to offspec material, causing recrushing cycles, wasted energy, and rejected loads.
High Maintenance Costs: Frequent liner changes, bearing failures, and structural wear require excessive parts inventory and mechanic hours.
Rigid Plant Configuration: Fixed systems cannot adapt to changing feed material or product requirements, limiting operational flexibility and contract bidding potential.
Rising Energy Consumption: Inefficient drive systems and process overwork directly inflate your most controllable operating expense.

Is your primary crushing station a reliable asset or a recurring liability? Can your screening plant deliver precise specification material shift after shift? The solution lies in selecting professional crushing and screening equipment engineered to address these exact operational and financial pressures.

2. PRODUCT OVERVIEW: MODULAR CRUSHING AND SCREENING PLANTS

This product category encompasses preengineered, semimobile processing systems that integrate primary crushing, secondary/tertiary crushing, and multistage screening into a single operational workflow. Designed for quarrying, mining, and largescale construction projects, these plants offer a balance of fixedplant performance with relocation flexibility.

Operational Workflow:
1. Primary Feeding & Crushing: Runofmine or blasted feed material is reduced by a robust jaw or gyratory crusher.
2. Primary Screening & Conveying: A highcapacity vibrating screen separates bypass material and directs sized feed to stockpile or secondary circuits.
3. Secondary/Tertiary Crushing: Cone crushers or impactors further reduce material to target dimensions in closedcircuit with screens.
4. Final Screening & Stockpiling: Multiple deck screens sort crushed material into precise product fractions conveyed to designated stockpiles.

Application Scope & Limitations:
Scope: Ideal for mediumtolarge scale aggregate production, virgin mineral processing (limestone, granite), C&D recycling operations requiring multiple products.
Limitations: Not suitable for underground mining or highly confined urban sites without significant space planning. Initial capital outlay is higher than standalone equipment purchases.

3. CORE FEATURES

Advanced Chamber Automation | Technical Basis: Hydroset CSS adjustment & realtime pressure monitoring | Operational Benefit: Operators can adjust crusher settings remotely for different products without stopping the process; protects the crusher from tramp metal damage through automatic release. | ROI Impact: Reduces downtime for product changeovers by up to 80% and prevents costly mechanical overload damage.

MultiAngle Vibrating Screen | Technical Basis: Independently driven screen decks with adjustable throw and frequency | Operational Benefit: Allows finetuning of stratification and conveyance for different materials on the same unit; reduces blinding on sticky feeds. | ROI Impact: Improves screening efficiency by 1525%, yielding more inspec product per ton processed.

Centralized PLC Control & Telematics | Technical Basis: Industrial programmable logic controller with cellular/GPS data transmission | Operational Benefit: Provides realtime data on production rates, power draw, machine health; enables predictive maintenance scheduling from any location. | ROI Impact: Lowers unplanned downtime by up to 30% through conditionbased alerts; optimizes fuel/power use.

HeavyDuty Conveyor System | Technical Basis: Channel frame design with impact beds & automated tensioning | Operational Benefit: Minimizes belt wear at transfer points; maintains optimal tension across temperature shifts for longer component life. | ROI Impact: Reduces conveyor maintenance costs by an average of 22% annually versus standard trussframe systems.

QuickSetup Modular Design | Technical Basis: Pinandwedge locking systems with prerun hydraulic/pneumatic lines | Operational Benefit: Reduces onsite assembly time from weeks to days using minimal heavy lifting equipment. | ROI Impact: Cuts mobilization/demobilization costs significantly, allowing faster deployment between sites or contract phases.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Modular Crushing Solution | Documented Advantage |
| : | : | : | : |
| Tons per Hour (TPH) Availability | 8588% availability over annual operation (excluding planned maintenance) |>92% availability over annual operation (excluding planned maintenance) |>4% improvement |
| Liner Change Time (Primary Crusher) | 1824 hours for jaw crusher mantle/liner replacement| 93% passing efficiency on final deck| ~5% increase in premium product yield |
| Specific Energy Consumption (kWh/ton processed)| Varies widely; baseline set at 100% for comparison.| Field data shows average reduction of 812%.| Up to 12% lower energy cost per ton |

_Availability defined as actual operating time / scheduled operating time._

5. TECHNICAL SPECIFICATIONS

Nominal Capacity Range: Configurable from 300 TPH to over 1,200 TPH depending on feed material hardness (e.g., Granite vs. Limestone).
Power Requirements: Primary plant electrical demand typically ranges from 400 kVA to 800 kVA; dieselelectric generator options available.
Material Specifications: Highstrength abrasionresistant steel (HARDOX® or equivalent) used in hoppers, chutes, skirting; Manganese steel crusher liners.
Physical Dimensions (Example Configuration): Primary module approx. L18m x W5m x H6m; total plant footprint typically between L60m x W25m.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dust suppression system standard; noise encapsulation packages optional.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: A southeastern US quarry needed to increase production by 40% but had limited space for expanding its fixed plant infrastructure within the existing pit boundary.
Solution: Implementation of a threemodule tertiary crushing plant equipped with two cone crushers operating in closed circuit with a tripledeck screen.
Results: The modular setup was commissioned within two weeks of delivery on a new bench location within the pit wall perimeter without disrupting existing operations—achieving a sustained output increase of over 42%.

LargeScale Infrastructure Contract

Challenge: A civil engineering contractor faced penalties for missing gradation specifications on a major highway project using recycled concrete aggregate (RCA), which contained problematic fines and rebar strands.
Solution Deployment of a specialized modular crushing plant featuring an electromagnetic separator on the feed conveyor and an aggressive washing screen module integrated into the secondary circuit.
Results: The system consistently produced DOTapproved RCA while removing over >99% of ferrous contaminants—eliminating load rejections—and allowed the entire setup to be relocated twice along the project corridor as work progressed.

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is structured around core configuration tiers based on maximum throughput capacity:

Tier I (800 TPH): Highoutput plants designed for maximum uptime in severeduty mining/quarrying

Optional features include advanced dust suppression fog cannons automated greasing systems remote camera monitoring packages extendedwarranty component bundles

Service packages are available from basic commissioning support upto comprehensive fullservice maintenance agreements that include planned parts replacement

Financing options encompass traditional equipment loans operating leases tailored rentaltoown structures designed match project cashflow cycles

8 FAQ

Q1 How do I determine if my site can accommodate this type of modular plant?
A site layout review conducted by our application engineers is standard procedure They will assess access topography foundation requirements utility hookups optimal flow—providing you with detailed plan prior commitment

Q2 What level operator training required?
We provide comprehensive onsite training covering normal operation troubleshooting basic maintenance procedures Documentation includes detailed manuals schematics Most clients find their experienced crews proficient within three five working days

Q3 Are these plants compatible with our existing conveyors stackers?
Yes interfaces are designed industrystandard heights widths Control systems can integrated into existing network via standardized communication protocols ensuring interoperability

Q4 What typical lead time from order commissioning?
For standard configurations lead times generally range between weeks depending current manufacturing cycle complexity Customized configurations may require additional engineering fabrication time which will be detailed during proposal phase

Q5 How does predictive maintenance telematics system actually work?
Sensors monitor key parameters vibration temperature pressure oil condition Data transmitted secure portal alerts generated when trends indicate potential issue This allows scheduling corrective action during planned stops rather than reacting catastrophic failure