1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? Na britagem e peneiramento, desafios comuns impactam diretamente seus resultados financeiros. Consider these frequent scenarios:
Tempo de inatividade não programado: Component failures in critical crushers or screen decks halt entire processing lines, custando milhares por hora em perda de produção e mão de obra.
Altos custos de manutenção: Mudanças freqüentes de rolamento, substituição de peças de desgaste, and manual adjustments consume both budget and maintenance team hours.
Gradação inconsistente do produto: Outofspec aggregate or mineral product leads to rejected loads, penalidades contratuais, e matéria-prima desperdiçada.
Inefficient Fuel/Power Consumption: Older or poorly configured equipment operates at low efficiency, with a significant portion of energy costs not translating to usable throughput.
Desgaste rápido em aplicações abrasivas: The financial burden of constantly replacing liners, telas, and blow bars in hard rock or slag processing is substantial.

What if your primary crushing station could deliver more tons between service intervals? How would predictable output gradation improve your downstream operations? The solution lies in selecting crushing and screening equipment engineered to address these exact operational and financial pressures.

2. VISÃO GERAL DO PRODUTO: MOBILE TRACKMOUNTED CRUSHING & PLANTA DE TRIAGEM

This product category refers to a selfcontained, trackmounted system that integrates primary crushing, britagem secundária/terciária, and screening modules into a single mobile unit. It is designed for onsite processing of quarried rock, concreto reciclado & asfalto (RCA), and natural stone.

Fluxo de Trabalho Operacional:
1. Alimentar & Britagem Primária: Raw material is loaded via excavator or wheel loader into a vibrating grizzly feeder (VGF VGF), which bypasses fines and directs oversize to the robust jaw crusher for initial size reduction.
2. Processamento Secundário & Triagem: Crushed material is conveyed to a cone crusher for further refinement. The output is then fed onto a highcapacity multideck screenbox.
3. Classificação de produtos & Estoque: The screen separates material into 35 specified grades (por exemplo, curso básico, pedra de drenagem, fichas). Oversize is recirculated via closedcircuit conveyors for recrushing, while onspec products are stockpiled by radial stackers.

Escopo de aplicação: Ideal for mediumtolarge scale contract crushing requiring relocation between sites (pedreiras, demolition yards, large civil works projects). Excellent for producing spec aggregate from virgin rock or recycled materials.

Limitações: Not suitable for underground mining or fixedplant installations requiring extreme longevity over mobility. Maximum feed size and hardness are constrained by the integrated primary crusher model.

3. RECURSOS PRINCIPAIS

Trituradores de acionamento direto | Base Técnica: Eliminação de correias trapezoidais e componentes associados | Benefício Operacional: Maior eficiência de transmissão de energia (até 96%) e pontos de manutenção reduzidos | Impacto do ROI: Lower fuel consumption per ton crushed and reduced risk of downtime from belt failure/slippage.

Independent PreScreen | Base Técnica: Vibrating grid section mounted before the crusher inlet | Benefício Operacional: Removes fines and sticky material prior to crushing chamber entry | Impacto do ROI: Reduces crusher cavity wear by up to 30% and prevents chamber packing, maintaining optimal throughput.

Ajuste Hidráulico & Limpeza | Base Técnica: Integrated hydraulic rams for CSS adjustment and uncrushable release | Benefício Operacional: Operators can adjust product size or clear blockages in minutes from ground level | Impacto do ROI: Minimiza o tempo de inatividade para ajustes de rotina em mais de 70% em comparação com sistemas de calços manuais.

Nível 4 Final / Estágio V DieselPropulsão Elétrica | Base Técnica: Diesel engine drives generators powering electric motors on tracks, alimentadores, e transportadores | Benefício Operacional: Significant fuel savings (dados de campo mostram 1525%), quieter operation, and precise control | Impacto do ROI: Direct reduction in operating cost per ton with compliance in all regulatory zones.

Sistema de controle inteligente baseado em PLC | Base Técnica: Programmable Logic Controller with color touchscreen interface | Benefício Operacional: Monitors production rates, Configurações CSS, consumo de energia, and alerts operators to anomalies | Impacto do ROI: Enables datadriven optimization for peak efficiency and provides diagnostic logs to preempt failures.

HeavyDuty Roller Bearing Construction | Base Técnica: Largediameter spherical roller bearings on eccentric assemblies | Benefício Operacional: Supports high radial and thrust loads with superior heat dissipation | Impacto do ROI: Extends bearing service life by 23x under severe duty cycles, adiando grandes custos de revisão.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Mobile TrackMounted Crushing & Solução para planta de triagem | Vantagem (% Melhoria) |
| : | : | : | : |
| Consumo de combustível (L/tonelada) | Hydraulic directdrive systems | Dieselelectric drive with loadsensing hydraulics| Até 25% melhoria |
| Tempo de troca de peças de desgaste (Forros de mandíbula)| Manual removal with overhead crane assist| Hydraulicassisted wedge system with lifting tool| Aproximadamente 50% mais rápido |
| Configurar / Tempo de desmontagem (between sites)| Multiple independent units requiring alignment| Singleunit integrated plant with hydraulic folding conveyors| Até 40% mobilização mais rápida |
| Consistência de gradação de produto (± % do alvo)| Manual CSS adjustment based on periodic sampling| Remote CSS adjustment via PLC with realtime feedback loop| Consistency improved by ~60% |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade/rendimento: Até 450 toneladas por hora (TPH), dependente da densidade do material de alimentação & dureza.
Triturador Primário: Maldito Mandíbula, feed opening up to 1m x 800mm.
Triturador Secundário: Cone Crusher with multiple crushing chamber options.
Caixa de tela: Peneira vibratória Tripledeck; area up to 7m² per deck.
Unidade de energia: EPA Tier 4 Final / EU Stage V diesel engine rated at 350 kW.
Especificações de materiais: Crusher liners manufactured from manganese steel (1822%). Chassis constructed from hightensile strength steel (S690QL).
Dimensões Físicas (Operando): Length ~27m; Largura ~4m; Altura ~5m.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Dust suppression system fitted as standard.

6. CENÁRIOS DE APLICAÇÃO

Agregado de concreto reciclado (RCA) Production Challenge:

A demolition contractor faced high landfill fees and missed revenue opportunities from concrete waste. Onsite crushing was hampered by rebar contamination causing frequent downstream blockages and inconsistent final product quality affecting sales price.

Solução:

Implementation of a mobile trackmounted plant featuring an electromagnetic overband magnet on the main conveyor and a robust jaw crusher capable of processing reinforced concrete chunks.

Resultados:

The plant processed over 250k tons of demolition concrete annually. Rebar removal exceeded 98%, eliminating blockagerelated downtime. The consistent RCA product commanded a 20% higher market price than uncertified material while eliminating $150k+ in annual tipping fees.

Granite Quarry Contract Crushing Challenge:

A quarry operator needed flexible capacity for a new granite deposit without capital investment in fixed infrastructure. Key concerns were extreme abrasiveness wearing out components rapidly and maintaining tight product specifications for a highway construction contract.

Solução:

Deployment of a tracked coneandscreen plant equipped with specialized abrasivegrade liners in the cone crusher an advanced automated control system that maintained closedside setting (CSS).

Resultados:

The plant achieved a sustained throughput of 380 TPH de granito duro. Wear life on cone mantles increased by approximately 40% compared to previous equipment used on the same material. Product gradation stayed within contract specifications for over 95% of sampled loads avoiding any penalties

7 CONSIDERAÇÕES COMERCIAIS

Equipment pricing tiers are typically structured around capacity core machine configuration:

Camada de configuração básica ($1M $1M): Includes standard jaw/cone/screen combination standard dust suppression basic control system
Nível de alta capacidade ($1M $1M): Features larger crushers additional prescreen option extended conveyors enhanced wear packages
Specialized Application Tier ($1M+): Customized with features like rock hammers grizzly bypass systems advanced air filtration

Optional features include onboard water pumps for dust suppression wireless remote control radial side conveyor for secondary stockpiling extra heavyduty wear liners

Service packages range from basic warranty extensions(12 months/2000 hours)to comprehensive fullmaintenance contracts covering all parts labor scheduled servicing

Financing options available include equipment leasing capital loans rentaltoown agreements tailored to match project cash flow cycles

8 Perguntas frequentes

Q What is the lead time from order commissioning?
A Standard configurations typically have lead time of months Customized units may require months depending specifications Current production schedules confirmed upon inquiry

Q Is this equipment compatible with existing support machinery?
A Yes These plants are designed work seamlessly with standard excavators wheel loaders haul trucks Industry standard interfaces ensure compatibility

Q How does this solution impact my site manpower requirements?
A The centralized PLC control system automated functions allow single operator manage entire crushing screening process effectively reducing required personnel compared multiunit setups

Q What commercial terms are available?
A We offer several structures including outright purchase finance lease operating lease Longterm rental agreements also available provide maximum flexibility

Q What does implementation look like onsite?
A Delivery includes supervised commissioning operator training period Our technicians ensure plant operational according specifications before handover Full documentation provided