1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? For plant managers and contractors overseeing bulk material processing, inefficient crushing and screening is a primary bottleneck. Os desafios comuns incluem:
High PerTon Cost: Inefficient flow, excessive recirculation, and frequent component wear directly increase your cost per ton of processed material.
Tempo de inatividade não programado: Unplanned stops for maintenance, bloqueios, or mechanical failures disrupt entire production schedules, causing significant revenue loss.
Gradação inconsistente do produto: Offspec material results in product rejection, custos de reprocessamento, e clientes insatisfeitos.
Rising Labor & Intensidade Energética: Equipment requiring constant monitoring, ajuste manual, or excessive power consumption drives up operational expenditures.
Limitações de escalabilidade: Fixed systems struggle to adapt to changing feed material or required product specifications, limiting contract flexibility.

Is your current setup equipped to maximize throughput while controlling these variables? A strategic investment in modern exportgrade crushing and screening equipment is not merely a capital purchase; it is a direct intervention on your bottom line.

2. VISÃO GERAL DO PRODUTO

This product line encompasses heavyduty, containerized crushing and screening plants engineered for highvolume primary, secundário, and tertiary processing of aggregates, minério, e minerais industriais. Designed for export and demanding site conditions, these systems transform raw feed into precisely graded end products.

Fluxo de Trabalho Operacional:
1. Redução Primária: Raw feed is introduced to a robust jaw or gyratory crusher for initial size reduction.
2. Triagem Primária & Transporte: Crushed material is conveyed to a primary screen deck where subsize product is separated; oversize is routed for further crushing.
3. Processamento Secundário/Terciário: Oversize material is directed to cone or impact crushers for additional reduction in closedcircuit with screening units.
4. Final Product Sorting: Multiple deck screens separate the processed material into 35 specified final product fractions.
5. Estoque: Finished products are conveyed to designated stockpiles or loading areas.

Escopo de aplicação: Ideal for largescale quarrying, mining preconcentration, grandes projetos de infraestrutura (base rodoviária, lastro ferroviário), and commercial aggregate production.
Principais limitações: Not suitable for ultrafine grinding (sub5mm) without specialized circuits; maximum feed size and hardness are defined by modelspecific engineering limits.

3. RECURSOS PRINCIPAIS

Geometria de Câmara Avançada | Base Técnica: Ângulo de aperto otimizado e perfil da cavidade de britagem | Benefício Operacional: Increases firstpass reduction ratio, minimizing recirculating load and wear on downstream components | Impacto do ROI: Reduces energy consumption per ton by up to 15% and extends liner life

Centralized Grease Automation | Base Técnica: Programmable, highpressure centralized lubrication system | Benefício Operacional: Ensures consistent bearing lubrication under all load conditions without manual intervention | Impacto do ROI: Lowers bearing failure risk by an estimated 70%, directly preventing costly unscheduled downtime

Flexibilidade de energia híbrida | Base Técnica: Configurable power train accepting grid connection or onboard dieselgenerator sets | Benefício Operacional: Enables rapid deployment to remote sites and provides operational resilience during grid instability | Impacto do ROI: Eliminates infrastructure delays; dados de campo mostram um 40% reduction in site commissioning time

Projeto de componentes modulares | Base Técnica: Bolttogether substructures with standardized interfaces | Benefício Operacional: Simplifies transport in standard containers and allows for strategic component replacement or future circuit reconfiguration | Impacto do ROI: Cuts international shipping costs by approximately 25% versus monolithic units

Intelligent Process Control (IPC) Sistema | Base Técnica: PLCbased system with load management and CSS adjustment capabilities | Benefício Operacional: Automatically regulates feed rates and crusher settings to maintain optimal throughput and product gradation | Impacto do ROI: Maintains consistent spec yield (>98%), reducing waste and reprocessing

HeavyDuty Vibrating Screen with Deck Access System | Base Técnica: High Gforce exciters mounted on reinforced decks with walkways | Benefício Operacional: Provides efficient material stratification and sizing even with sticky or damp feed; allows safe, quick media changes | Impacto do ROI: Improves screening efficiency by 20%, boosting overall plant capacity

Supressão de poeira integrada & Redução de ruído | Base Técnica: Spray bar systems at transfer points with acoustic encapsulation panels | Benefício Operacional: Meets stringent international environmental compliance standards for particulate matter and noise pollution | Impacto do ROI: Mitigates project delay risks from regulatory noncompliance and community complaints

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Nosso esmagamento & Solução de triagem | Vantagem (% melhoria) |
|||||
| Toneladas por hora (TPH) / kW | Varia de acordo com o aplicativo | Optimized flow design & eficiência de condução | +1015% Eficiência Energética |
| Tempo de troca do revestimento | 812 horas (jaw/cone) | Ajuste hidráulico & assisted tooling |35% Tempo de inatividade |
| Screening Efficiency ~8590% Patented throw & deck design +1012% Colheita |
| Tempo médio entre falhas (Rolamentos Críticos) ~1218 months Premium seals & grease automation +50% Vida útil |
| OnSite Assembly Duration ~1014 days Preassembled modular skids 40% Tempo de comissionamento |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 300 para 1,200 toneladas métricas por hora (TPH), depending on feed material (densidade aparente ~1,6 t/m³) and product gradation.
Requisitos de energia: Primary plant power range from 250 kVA para 800 kVA. Available as 50Hz or 60Hz compliant. Hybrid option includes integrated Stage V/Tier 4 Final diesel generators.
Especificações de materiais: Highabrasion steel wear plates (HB400+); Crusher mantles/concaves in premium manganese steel (18%22%); Screen decks in rubberpolyurethane composite or woven wire mesh.
Dimensões Físicas (Typical Primary Unit): Transportable within standard highcube containers. Assembled dimensions approx.: Length 25m x Width 7m x Height 5m.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Dust suppression system rated for control below 10 mg/m³ at emission points.

6. CENÁRIOS DE APLICAÇÃO

Granite Quarry Expansion – Southeast Asia

Challenge A quarry operation needed to increase output by 60% to fulfill a new highway contract but was constrained by space limitations and a dated twostage plant with high fines production.
Solution Implementation of a compact threestage trackmounted crushing circuit featuring an advanced cone crusher in closed circuit with a tripledeck screen.
Results The new setup achieved a 65% throughput increase within the same footprint while improving yield of valuable chip products by 22%. Payback was achieved in under 14 months through the contract fulfillment.

Iron Ore Scalping & PreConcentration – West Africa

Challenge A mining operation faced high processing costs due to transporting lowgrade waste rock through the entire primary circuit.
Solution Integration of an ultraheavyduty grizzly scalper ahead of the primary crusher station to remove barren waste rock (>250milímetros).
Results Field data shows over 30% of total volume was rejected at the scalp level, significantly reducing energy consumption and wear in the downstream crushing stages. This increased effective plant capacity without adding new primary crushers.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Solutions are offered across three tiers:
Padrão: Highefficiency base plant for common aggregate applications.
HighAbrasion: Upgraded wear packages for abrasive feeds like granite/basalt.
MiningSpec: Reinforced structures & components for heavyfeed ore applications.

Recursos opcionais: Onboard weighing systems, sistemas automatizados de detecção de metais/alívio de tramp,
remote telematics for performance monitoring,
extra dust encapsulation packages.

Pacotes de serviços: Choose from annual inspection plans,
wearsandspares contracts with guaranteed supply,
or fullsite service agreements including labor.

Opções de financiamento: We work with export credit agencies
to provide project financing,
and offer leasetoown structures
to align payment schedules with your cash flow from project milestones.

8. Perguntas frequentes

Q1 Are these plants compatible with our existing conveyors stackers?
A1 Yes within defined engineering parameters The control system can be integrated Standard discharge heights conveyor widths belt speeds are documented Our engineering team can perform a compatibility review based on your existing layout drawings

Q2 What is the expected operational impact during the transition from our old plant?
A2 With modular design the objective is minimal disruption Preassembly testing minimizes onsite commissioning A phased implementation over weeks can be planned typically allowing partial operation of your legacy system during cutover

Q3 How do you guarantee performance metrics like throughput gradation
A3 Performance guarantees are based on certified test reports using customersupplied sample materials These form part of the commercial contract Guarantees cover capacity power consumption key wear part life under defined operating conditions

Q4 What are typical lead times from order placement delivery
A4 For standard configured plants lead time ranges between months depending on model complexity Custom configurations may require additional engineering time All timelines are confirmed upon project specification

Q5 What training is provided for our operations maintenance teams
A5 Comprehensive training is included covering daily operation routine maintenance troubleshooting safety procedures Training occurs during commissioning both classroom instruction handson equipment familiarization Manuals schematics provided digitally permanently accessible