1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? Para gerentes de fábrica e empreiteiros, the crushing and screening circuit is often the bottleneck where inefficiencies translate directly into lost revenue. Os desafios comuns incluem:
Tempo de inatividade não programado: Falhas em componentes em britadores ou peneiras críticas paralisam linhas de produção inteiras, costing thousands per hour in idle labor and delayed project timelines.
Altos custos de manutenção: Frequent wear part replacement and reactive repairs create unpredictable OPEX, straining maintenance budgets.
Gradação inconsistente do produto: Outofspec aggregate leads to product rejection, custos de reprocessamento, and damage to your reputation for quality.
Aumento do consumo de energia: Inefficient drives and outdated material flow designs result in excessive power draw per ton of processed material.
Configuração de planta rígida: Fixed systems cannot adapt to changing feed material or product requirements, limitando a flexibilidade operacional.

Is your current equipment contributing to these problems? O que seria um 1520% improvement in overall plant availability mean for your annual throughput?

2. VISÃO GERAL DO PRODUTO

Our core offering is a comprehensive range of stationary, modular, and trackmounted equipamento de britagem e peneiramento, engineered as integrated systems for highvolume aggregate production and mineral processing. The operational workflow is designed for continuous, efficient material reduction:

1. Britagem Primária: Feed material is reduced by jaw or gyratory crushers to a manageable size for downstream processing.
2. Triagem Primária & Transporte: Scalping screens remove fines and bypass material, while heavyduty conveyors transfer crushed product.
3. Britagem Secundária/Terciária: Cone or impact crushers further refine the material to the target particle size.
4. Triagem Final & Classificando: Multideck vibrating screens accurately separate the crushed material into specified product fractions (por exemplo, agregados, fichas, areia).
5. Estoque & Recirculação: O produto Onspec é transportado para estoques; oversize material is automatically recirculated back into the circuit.

Escopo de aplicação: Ideal para extração em grande escala, pré-concentração de mineração, construção & reciclagem de demolição, and aggregate production plants processing hard rock (granito, basalto) e materiais abrasivos.

Limitações: Não projetado para retificação ultrafina (sub5mm) requiring specialized mills or for processing highly viscous or claybound materials without preprocessing.

3. RECURSOS PRINCIPAIS

Geometria de Câmara Patenteada | Base Técnica: Ângulo de aperto otimizado e perfil da cavidade de britagem | Benefício Operacional: Aumenta a taxa de redução da primeira passagem, reducing load on secondary crushers and minimizing recirculating load | Impacto do ROI: Os dados de campo aparecem até 8% higher throughput with same power input.

Design de moldura modular | Base Técnica: Aparafusados, highstrength steel sections with precisionmachined interfaces | Benefício Operacional: Enables faster site assembly, future reconfiguration, and reduced transport costs versus welded unitary frames | Impacto do ROI: Reduces plant commissioning time by an estimated 30%, accelerating revenue generation.

Lubrificação Centralizada & Monitoramento de condição | Base Técnica: Automated lubrication system with integrated pressure/sensor ports at all major bearing points | Benefício Operacional: Garante a saúde ideal do rolamento, estende os intervalos de manutenção em até 25%, and provides early failure warning | Impacto do ROI: Lowers planned maintenance labor hours by ~15% and prevents catastrophic bearing failures.

Hybrid Drive System Options | Base Técnica: Direct dieselelectric or mainspowered drives with hydraulic adjustment systems | Benefício Operacional: Offers fuel efficiency in remote locations or grid stability for fixed plants; provides rapid crusher setting adjustments under load | Impacto do ROI: Os testes da indústria demonstram até 12% lower fuel consumption in hybrid mode versus traditional direct diesel drives.

HighStrength Screen Media Systems | Base Técnica: Interchangeable polyurethane, borracha, or woven wire panels with tensioning systems | Benefício Operacional: Increases screen media service life by resisting blinding and abrasion; allows quick panel changeout (<2 horas) | Impacto do ROI: Reduces screen media inventory costs and associated downtime by improving changeout efficiency.

Controle Inteligente de Processo (CIP) Integração | Base Técnica: PLCbased system with feed rate/weight detection and crusher load management algorithms | Benefício Operacional: Automatically optimizes feed for maximum throughput without choking; protects equipment from tramp metal damage via instant stop commands | Impacto do ROI: Maximizes yield of inspec product while safeguarding against costly unplanned stoppages.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nosso esmagamento & Vantagem documentada da solução de triagem |
| : | : | : |
| Vida útil da peça de desgaste do britador (Mn18/22) | ~450550k MT throughput (hard abrasive granite) |
| ~600700k MT throughput |
| +2025% vida mais longa |
| Screen Panel ChangeOut Time (Primary Scalper) |
| ~46 hours |
| 92% |
| +47% absolute improvement |
| Consumo de Energia por Tonelada Processada |
| Linha de base = 100% |
| Average reduction to ~9092% of baseline |
| 810% melhoria |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 200 TPH modular plants to 1,500+ Instalações estacionárias TPH.
Opções do britador primário: Britadores de mandíbulas (900x1200mm to 1500x2000mm feed opening); Trituradores giratórios (42” – 60”).
Requisitos de energia: Plantwide demand from 300 kVA (modular) para 1500+ kVA (large stationary plant). Hybrid genset options from 500 kVA.
Especificações de materiais: Main frame fabrications from S355JR steel; critical wear parts in Mn18Cr2/Mn22Cr2 alloys; shafting from forged 42CrMo4 steel.
Dimensões Físicas (Example Modular Jaw Plant): Aprox.. L20m x W4m x H5.5m (transport configuration).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 25°C a +45°C; dustproofed electrical components to IP65 standard; optional Arctic packages available.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Challenge A quarry operator needed to increase annual output by 35% but was constrained by an aging singleline plant with frequent breakdowns causing over 300 hours of unscheduled downtime annually.
Solution Implementation of a turnkey threestage crushing and screening plant featuring a primary jaw crusher, two secondary cone crushers in parallel configuration, and a large tripledeck finishing screen.
Results Plant availability increased to 93%. Throughput targets were met within six months of commissioning. Annual unscheduled downtime was reduced by over 70%, translating directly into an additional €220k in annual gross profit at their selling price.

C&D Empreiteiro de Reciclagem

Challenge A growing recycling business faced high contamination rates in final aggregate products due to inefficient screening of lightweight debris (madeira, plásticos), leading to product rejection.
Solution Integration of a highfrequency screening unit with wind sifter technology into their existing trackmounted impact crushing circuit.
Results Final product purity improved from ~92% to over 98%, eliminating rejection fees from readymix concrete customers. The recovered lightweight fraction was compacted for alternative fuel use, creating a new revenue stream.

7. CONSIDERAÇÕES COMERCIAIS

Our pricing structure is based on a modular system allowing you to scale investment according to current needs:

Tier I – Core Equipment Package: Includes primary crusher module(é), primary screen module(é), base conveyors/feeders/electrics at OEM factory wholesale price.
Tier II – Complete Process Line: Tier I plus secondary/tertiary crushing modules(é), final sizing screens(é), full conveyor circuit integration control system integration package (+1525% over Tier I).
Tier III – Turnkey Project Scope Full engineering support civil design foundation drawings onsite supervision commissioning services (+4060% over Tier I).

Optional Features Advanced dust suppression fog cannons automated sampler systems remote telemetry packages extended wear part kits

Service Packages Available include scheduled inspection plans parts supply agreements fullscope maintenance contracts

Financing Options We work with international export credit agencies project finance partners equipment leasing companies provide flexible terms support capital expenditure planning

8.Perguntas frequentes

Q What level of ground preparation required installation?
A Our modular skidmounted designs require simple concrete footings minimal civil works significantly reducing site preparation time cost compared pouredinplace foundations

Q How does your equipment handle variations feed material hardness?
A Our crushing chambers drive systems are designed handle reasonable fluctuations Adjustable hydraulic settings allow operators quickly compensate changes CSS maintain consistent product gradation

Q What typical lead time delivery?
A For standard configured modules lead time typically ranges between weeks depending complexity Custom engineered solutions may require longer detailed engineering phase We provide transparent milestonebased schedule upon order confirmation

Q Are your machines compatible existing thirdparty conveyors auxiliary equipment?
A Yes Our control systems designed standard communication protocols Interface points are clearly defined facilitate integration into brownfield sites Existing equipment can often be incorporated upgraded plan

P Qual cobertura de garantia é fornecida?
A We offer months comprehensive warranty covering defects materials workmanship Specific wear parts consumables like liners screen media are covered under separate prorated terms Warranty details are explicitly stated commercial agreement

Q Do you provide operator training?
A Yes Comprehensive training conducted during commissioning covers safe operation routine maintenance basic troubleshooting Training manuals digital resources are provided standard Documentation available multiple languages upon request