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, traditional crushing and screening setups often present persistent challenges: gradação inconsistente do produto final, levando a cargas rejeitadas, excessive wear part consumption due to inefficient chamber designs, and high labor costs from manual adjustments and blockages. Esses problemas impactam diretamente seus resultados financeiros por meio do desperdício de material, unscheduled maintenance, e horas de produção perdidas.

Como você pode alcançar resultados consistentes, inspec aggregate output while controlling operational expenditure? Is there a way to reduce unplanned downtime and extend service intervals without compromising throughput? The solution lies in specifying equipment engineered not just for peak performance, mas para previsível, costeffective operation across its lifecycle.

2. VISÃO GERAL DO PRODUTO

This product line encompasses a comprehensive range of stationary and trackmounted export crushing and screening equipment designed for private label manufacturing partners. The operational workflow is engineered for linear efficiency: (1) Primary feeding and size reduction via jaw or impact crushers, (2) Intermediate sizing and stockpiling with cone crushers and screens, (3) Final precision screening for product separation, (4) Recirculation of oversize material, e (5) Integrated conveying for seamless material flow.

This equipment is applicable for medium to largescale aggregate production, C&Reciclagem D, and nonabrasive mineral processing. It is optimally designed for processed natural stone and recycled concrete; limitations exist for highly abrasive or chemically aggressive materials without specific liner configurations.

3. RECURSOS PRINCIPAIS

Ajuste CSS do Hydroset | Base Técnica: Pistão hidráulico que suporta o eixo principal | Benefício Operacional: Configuração fechada (CSS) adjustments can be made in under 60 seconds under load, enabling rapid product size changes. | Impacto do ROI: Reduces nonproductive time by up to 80% em comparação com sistemas de calços manuais, aumentando a flexibilidade da planta.

Sistema modular de retenção de revestimento | Base Técnica: Mechanically locked liner segments with wedge bolts | Benefício Operacional: Eliminates backing compound use, reduz o tempo de troca do revestimento em uma média de 40%. | Impacto do ROI: Lowers labor costs per maintenance event and increases crusher availability.

Nível 4 Final / Stage V Compliant Power Unit | Base Técnica: Advanced diesel engine with integrated SCR/DPF technology | Benefício Operacional: Provides full power while meeting global emissions standards without derating. | Impacto do ROI: Ensures regulatory compliance for export markets and avoids potential site operating restrictions.

Independent PreScreen & ByPass Conveyor | Base Técnica: Dedicated vibrating grid before the crusher inlet with a direct fines conveyor | Benefício Operacional: Removes natural fines from the feed stream, reducing crusher chamber volume consumption and wear. | Impacto do ROI: Increases effective throughput of valuable material by up to 30% and extends wear part life.

Sistema de controle de planta baseado em PLC | Base Técnica: Controlador lógico programável centralizado com IHM touchscreen | Benefício Operacional: Allows singlepoint monitoring of all plant functions, taxas de alimentação, e diagnóstico. Enables automated startup sequences. | Impacto do ROI: Minimizes operator error, optimizes power consumption per ton crushed, and provides actionable data for preventative maintenance scheduling.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Export Crushing & Solução de triagem | Vantagem (% melhoria) |
| : | : | : | : |
| Tempo de troca do revestimento (Triturador Primário) | 1624 horas (tripulação de 3) | 812 horas (tripulação de 3) | ~50% mais rápido |
| Fuel Consumption per Ton Crushed| 0.8 1.2 liters/tonne| 0.65 0.9 liters/tonne| ~20% mais eficiente |
| Eficiência de triagem (Middeck) | ~85% material separation| ~92% material separation| ~8% improvement |
| Tempo médio entre falhas (Sistema Hidráulico)| ~2.000 horas| ~3,200 hours| ~60% longer |

_(Based on field data from comparable installations processing granite/C&D waste.)_

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 150 para 600 tonnes per hour for hard rock applications.
Requisitos de energia: Primary plant options from 250 kVA para 800 kVA electrical; Trackmounted units feature diesel engines from 300 kW para 450 kW.
Especificações de materiais: Highstrength steel chassis; Crusher jaws/mantles in standard Mn14%18% or optional chrome iron alloys; Screen decks in hightensile woven wire or polyurethane panels.
Dimensões Físicas (Exemplo Primário + Planta de triagem): Approximate footprint of 32m L x 18m W x 12m H. Trackmounted units comply with standard transport width regulations.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 25°C a +45°C. Dust suppression system rated at ≤50mg/Nm³ emission control.

6. CENÁRIOS DE APLICAÇÃO

Aggregate Quarry Expansion in Southeast Asia

Desafio: A quarry operator needed to increase production of three certified aggregate products but faced space constraints preventing a traditional fixed plant expansion.
Solução: Implementation of a multistage trackmounted export crushing and screening equipment setup featuring a primary jaw crusher with independent prescreen, britador de cone secundário, and tripledeck finishing screen.
Resultados: Achieved required production increase of over 35% within the existing site footprint within one week of commissioning; reduced offspec product by approximately 15%.

Urbano C&D Recycling Operation in Europe

Desafio: High contamination rates in feed material caused frequent blockages in secondary crushers and inconsistent final recycled aggregate quality.
Solução: Integration of a heavyduty scalping screen ahead of the primary crusher circuit within their new private label crushing system.
Resultados: Reduced unscheduled downtime due to blockages by an estimated 70%, producing a cleaner final product that commanded a higher market price per ton.

7. CONSIDERAÇÕES COMERCIAIS

O equipamento é oferecido em três níveis principais:
1. Dever Padrão: Para materiais de alimentação consistentes como calcário; includes core features with standard wear parts.
2. Serviço Pesado: For mixed or abrasive feeds like granite/C&D; includes upgraded liners, heavierduty bearings/belts.
3. Modular SkidMounted: Preassembled modules for rapid deployment on concrete foundations.

Os recursos opcionais incluem canhões avançados de supressão de poeira,
sistemas de detecção de metais,
e pacotes de telemetria remota.
Os pacotes de serviços vão desde suporte básico de comissionamento
to comprehensive annual maintenance contracts
with guaranteed parts availability SLAs.
Financing options are structured through partner institutions,
offering operating lease or capital purchase plans
tailored to project cash flow requirements.

8.Perguntas frequentes

1º trimestre: Is this equipment compatible with our existing conveyors or screens?
A1: Yes.The modular design allows integration into existing circuits.Critical interface points such as discharge heights,larguras de cinto,and control system protocols are finalized during the engineering phase prior to manufacturing.

2º trimestre:Qual é o impacto operacional esperado em nossa força de trabalho atual?
A2:The automation features reduce manual intervention,but training is provided.The centralized PLC control system typically requires fewer operators for monitoring,but shifts their role towards process optimization rather than manual adjustment.Field data indicates a training period of one week is standard for operators familiar with similar machinery

3º trimestre:Quais são os prazos de entrega típicos,and what commercial terms are offered?
A3 Lead times vary by configuration,variando de 12 weeks for standard designs 24 weeks+for fully custom plants.Commercial terms typically involve progress payments tied to key manufacturing milestones,FOB origin Incoterms are standard

Q4 How do you ensure spare parts availability under a private label agreement?
A4 We maintain consignment stock programs at regional logistics hubs based on forecasted demand.Partner portals provide realtime parts inventory visibility,and critical component kits are specified at pointoforder

Q5 What site preparation is required prior commissioning?
A5 A detailed site preparation document is supplied.General requirements include level compacted ground adequate crane access provision utilities water electricity fuel drainage The foundation design drawings are provided as part technical documentation