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 reliability of crushing and screening equipment directly dictates profitability. Os desafios comuns incluem:
Tempo de inatividade não programado: Falhas em componentes em britadores ou peneiras críticas paralisam linhas de produção inteiras, custando milhares por hora em perda de produção e mão de obra.
Altos custos de manutenção: Mudanças freqüentes de rolamento, substituições de revestimento, and vibration issues lead to excessive parts inventories and skilled labor overhead.
Qualidade de produto inconsistente: Inefficient screening and improper crushing chamber dynamics yield offspec aggregate, reducing saleable product volume.
Aumento do consumo de energia: Mais velho, inefficient drive systems and poorly optimized material flow place an unsustainable burden on your power costs.
Limitações de configuração rígida: Fixed plant layouts struggle to adapt to changing feed materials or final product specifications, limitando a flexibilidade operacional.

Is your current equipment portfolio a source of constant cost management rather than a reliable foundation for growth? The solution lies in specifying machinery engineered to address these exact operational and financial pressures.

2. VISÃO GERAL DO PRODUTO

This product line encompasses a comprehensive range of highperformance stationary and mobile crushing and screening plants available for private label manufacturing. Engineered for primary, secundário, terciário, and quaternary reduction stages, this equipment processes quarry rock, concreto reciclado, asfalto, e minerais industriais.

Fluxo de Trabalho Operacional:
1. Alimentação Primária & Esmagamento: Scalpers or grizzly feeders regulate material flow into robust jaw or primary impact crushers for initial size reduction.
2. Material Conveying: Highcapacity belt conveyors with impactresistant idlers transport crushed material to subsequent stages with minimal spillage and wear.
3. Britagem Secundária/Terciária & Triagem: Cone crushers or further impactors provide precise reduction. Integrated screens classify material, routing sized product to stockpiles and oversize back for further processing.
4. Estoque de produto final: Radial stackers or fixed conveyors create precisely blended stockpiles of finished aggregates.

Escopo de aplicação: Ideal for largescale aggregate production, pré-beneficiamento de mineração, construção & reciclagem de demolição, and road base preparation.
Limitações: Não projetado para retificação ultrafina (sub5mm) requiring specialized mills or for processing highly abrasive materials without specific liner alloy configurations.

3. RECURSOS PRINCIPAIS

Geometria de Câmara Patenteada | Base Técnica: Cinemática otimizada & perfil de cavidade | Benefício Operacional: Aumenta o rendimento em 1015% while maintaining consistent product gradation and reducing crusher bottlenecking. | Impacto do ROI: Higher tonsperhour output directly lowers costperton metric.

Sistema de lubrificação centralizado | Base Técnica: Automatizado, programmable lubrication to all major bearing points from a single station. | Benefício Operacional: Elimina erros de lubrificação manual, extends bearing service life by up to 40%, and improves site safety. | Impacto do ROI: Reduces lubrication labor hours by 70% and prevents costly premature bearing failures.

Sistema de mídia de tela modular | Base Técnica: Quicktensioning wedge system for panel changeout. | Benefício Operacional: Screen deck media can be replaced by two personnel in under one hour versus a halfday shift. | Benefício Operacional: Minimizes downtime during product changeovers or maintenance events.

Hybrid Power Unit Option | Base Técnica: Dieselelectric drive system with power management software. | Benefício Operacional: Enables peakload sharing, reduces fuel consumption by up to 25% in variable load conditions compared to standard dieselhydraulic systems. | Impacto do ROI: Significant reduction in operating fuel costs over the equipment lifecycle.

Estrutura fabricada para serviços pesados | Base Técnica: Análise de Elementos Finitos (FEA) designed steel construction with continuous welds at stress points. | Benefício Operacional: Provides exceptional structural integrity under dynamic loads, resisting fatigue cracks that lead to major frame repairs.| Impacto do ROI: Extends structural life of plant chassis beyond industry average, protecting capital asset value.

Sistema de controle PLC avançado | Base Técnica: Controlador lógico programável industrial com interface homem-máquina (IHM) for process monitoring.| Benefício Operacional: Operators can adjust settings, track production data, and diagnose faults from a central location.| Impacto do ROI: Enables datadriven decision making to optimize efficiency and simplifies troubleshooting.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Nosso esmagamento & Solução de triagem | Vantagem (% melhoria) |
| : | : | : | : |
| Vida útil do revestimento do britador (Rocha Abrasiva) | ~450500 hours Manganese Steel| ~600650 hours with proprietary alloy blend| +25% increased wear life |
| Tempo de troca do deck de tela| 46 horas (23 pessoal)| <1 hora (2 pessoal)| ~80% reduction in downtime |
| Consumo Médio de Energia (por tonelada processada)| Linha de base (100%)| Unidades otimizadas & projeto de câmara| Até 15% redução |
| Plant ReLocation & Tempo de configuração (Unidades Móveis)| 812 hour typical range| 46 hours with hydraulic assists & prerouted cabling| Implantação cerca de 50% mais rápida |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 150 TPH acima 800 TPH for complete plant systems.
Requisitos de energia: Acionamentos primários do britador de 75 kW para 400 kW; a carga total conectada da planta varia de acordo com a configuração; available for global voltage standards (50/60hertz).
Especificações de materiais: Estruturas de aço de alta resistência (S355J2); AR400 abrasionresistant steel at wear points; Rolamentos de qualidade superior; Optional chromewhite iron or composite liners.
Dimensões Físicas (Mobile Jaw Unit Example): Working length ~15m; Altura ~4m; Largura ~3m; Transport weight approx. 45 toneladas (varia).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; Dust suppression system compliant; Noise emissions designed to meet <85 dB(UM) nas estações da operadora.

6. CENÁRIOS DE APLICAÇÃO

Aggregate Producer – Hard Granite Quarry

Desafio: A Southeast US quarry faced excessive cone crusher mantle/bowl liner wear (~400hr life) causing high parts costs and unpredictable stoppages during peak demand.
Solução: Implementation of a tertiary crushing station featuring our cone crusher with patented chamber geometry and optional ultraabrasion resistant liner package.
Resultados: Vida útil do revestimento estendida para mais 600 hours—a documented 50% increase—reducing annual liner costs by approximately $85,000 USD and stabilizing the production schedule.

C&D Recycling Contractor – Urban Redevelopment

Desafio: A contractor needed rapid sitetosite mobility between projects while processing reinforced concrete with high rebar content without constant jams.
Solução: Deployment of a trackmounted mobile impact crushing plant equipped with an overband magnet system reinforced hydraulic drive protection against uncrushables.
Resultados: Plant relocation time reduced to under five hours per move. The system’s design eliminated catastrophic downtime from rebar entanglement increasing overall availability by an estimated 30%, allowing completion of two additional projects within the annual schedule.

Mining PreBeneficiation – Iron Ore

Desafio: A processing facility required consistent 40mm feed from lump ore but experienced frequent screen blinding due to high moisture content in seasonal periods.
Solução: Integration of our highfrequency linear vibrating screen deck featuring the modular tensioning system nonblinding polyurethane panels
Resultados: A disponibilidade da tela aumentou de 95%. The quickpanel change system allowed rapid adaptation panel types based seasonal feed conditions minimizing process upsets

Considerações Comerciais

Equipment is offered through tiered pricing aligned with configuration complexity:

Tier I – Base Mobile Unit Standard features single crushing stage basic screening
Tier II – Pro Configuration Includes hybrid power option advanced automation secondary crushing circuit
Tier III – Custom Plant Fully engineered stationary semistationary solution tailored specific material flow capacity requirements

Optional Features Hydraulic adjustment systems dust encapsulation packages winterization kits remote monitoring telemetry

Pacotes de serviços disponíveis:
1) Basic Warranty – Standard parts labor coverage months
2) Extended Protection Plan – Comprehensive coverage up months including wear components
3) Full Service Agreement – Scheduled maintenance inspections priority parts dispatch guaranteed response times

Financing Options Flexible commercial leasing capital equipment loans operating lease structures available through partnered financial institutions facilitating cash flow management

Perguntas frequentes

What level customization available private label program?
We offer extensive customization from component branding full engineering collaboration develop unique model designations meet your specific market requirements technical specifications

How does equipment integrate existing plant infrastructure?
Our engineering team provides interface drawings specifications ensure compatibility existing conveyors feeders electrical supply Control systems designed communicate via standard industrial protocols Modbus OPC UA)

What typical lead time commissioning after order placement?
Lead times vary configuration complexity For standard mobile units delivery typically within weeks Custom stationary plants require detailed engineering project timeline provided upon scope finalization Commissioning supervised our technicians included purchase

What key operator training maintenance support provided?
Comprehensive training conducted onsite covering safe operation routine maintenance troubleshooting procedures Detailed manuals schematics provided digitally Ongoing technical support available via dedicated hotline

São oferecidas garantias de desempenho?
Yes we provide guaranteed minimum throughput capacity product gradation curves based agreed feed material characteristics These are validated during factory acceptance testing commissioning

What are payment terms minimum order quantities?
Standard terms require deposit order confirmation balance prior shipment MOQs apply private label program discussed confidentiality agreement