1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão prejudicando a lucratividade da sua planta? In industrial crushing and screening, common challenges directly impact your bottom line. Excessive wear part consumption leads to frequent, costly replacements and unplanned maintenance windows. Inconsistent feed material causes fluctuating product gradation, resulting in outofspec material and rejected loads. Energyintensive processes consume disproportionate power without corresponding output gains. Além disso, frequent clogging and bridging in the circuit halt entire production lines, while complex maintenance procedures keep skilled technicians occupied for hours instead of optimizing throughput.

How do you transition from reactive repairs to predictive, costcontrolled operations? The solution lies in selecting industrial crushing and screening equipment engineered to convert these pain points into measurable efficiency gains.

2. VISÃO GERAL DO PRODUTO

This product line encompasses heavyduty stationary and semimobile crushing plants and screens designed for hightonnage mineral processing, produção agregada, e reciclagem de materiais de construção. The operational workflow is engineered for continuous, closedcircuit operation: (1) Primary feed is reduced by a jaw or gyratory crusher. (2) Material is conveyed to a secondary cone or impact crusher for further reduction. (3) Sized material is routed via conveyor to a multideck vibrating screen for classification. (4) Onspec product is diverted to stockpile, while oversize material is recirculated back into the secondary or tertiary crusher.

This equipment is applicable for processing hard rock (granito, basalto), minérios abrasivos, calcário, e concreto/asfalto reciclado. It is not designed for lowvolume, batch processing or for materials with high plasticity or clay content without specific preprocessing.

3. RECURSOS PRINCIPAIS

Modular Chamber Design | Base Técnica: Interchangeable crushing chamber profiles and eccentric throws. | Benefício Operacional: Enables quick reconfiguration from secondary to tertiary application or between different product shapes without major component changeouts. | Impacto do ROI: Reduces capital expenditure for a dedicated tertiary crusher by up to 40% in flexible plant designs.

Ajuste CSS do Hydroset | Base Técnica: Hydraulic system for Closed Side Setting (CSS) adjustment under load.| Benefício Operacional: Allows operators to finetune product size in under 60 seconds without stopping production, adapting to changing feed conditions in realtime.| Impacto do ROI: Eliminates production stoppages for manual shim adjustments, preserving an estimated 2030 hours of annual uptime per crusher.

Patented Screenbox Motion | Base Técnica: HighGforce linear or elliptical vibration drive technology tailored to material type.| Benefício Operacional: Prevents blinding and pegging of screen meshes while maintaining high stratification efficiency for accurate sizing.| Impacto do ROI: Increases screening efficiency by up to 15%, reducing recirculating load on crushers and lowering energy cost per ton.

Wear Part Monitoring System | Base Técnica: Embedded sensor technology paired with IoTenabled wear tracking software.| Benefício Operacional: Provides realtime data on liner thickness and predicts optimal changeout times based on actual wear rates, not just hours operated.| Impacto do ROI: Maximizes usable wear part life by 1218% on average and allows maintenance scheduling during planned outages, avoiding catastrophic failure.

Direct Drive Crusher Transmission | Base Técnica: Elimination of Vbelts via direct coupling of motor to crusher drive.| Benefício Operacional: Increases power transmission efficiency by approximately 5%, reduz pontos de manutenção (no belt tensioning), and lowers overall installed footprint.| Impacto do ROI: Direct energy savings coupled with reduced spare parts inventory (cintos, sheaves) yield a typical payback period under 24 meses.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Nosso esmagamento & Solução de triagem | Vantagem (% melhoria) |
| : | : | : | : |
| Tons per kWh (Eficiência Energética) | Measured baseline from legacy equipment surveys. | Geometria otimizada da câmara & direct drive systems reduce specific energy consumption. | Até 812% melhoria |
| Custo da peça de desgaste por tonelada processada | Based on standard manganese steel compositions & perfis. | Proprietary alloy formulations & engineered laminating crushing zones extend service life. | 1525% reduction demonstrated |
| Tempo médio entre falhas (MTBF) – Drives/Screens | Average intervals from industry maintenance reports. | Heavyduty bearing assemblies & balanced mass design reduce stress on components. | 30%+ increase documented |
| Screening Accuracy / Fines Yield Control| Standard singlefrequency screen box performance.| Multifrequency capable drives optimize particle travel speed & trajectory per deck.| Fines yield control improved by up to 10% |

5.ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 200 TPH acima 1,500 TPH primary crushing circuits.
Requisitos de energia: Plantwide requirements range from 400 kW para 1.5 PM; supplied for global voltages (380V480V/5060Hz). Crusher motors typically 200450 kW cada.
Especificações de materiais: Fabricated from hightensile steel plate; Crusher liners available in multiple grades of manganese steel (14%22%) or optional chromewhite iron alloys; Screen decks in hardened steel wire mesh or polyurethane panels.
Dimensões Físicas (Sample Primary Unit): Feed hopper: ~12m³; Crusher itself: L~5m x W~3m x H~4m; Total station footprint including feeders: ~25m x 15m.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 25°C a +45°C; dustsealed bearings and drives; sounddampened enclosures available to meet <85 dB(UM) nas estações da operadora.

6\. CENÁRIOS DE APLICAÇÃO

[Aggregate Producer – Granite Quarry]

Desafio: A quarry faced inconsistent cubicity in final aggregate products due to fluctuating rock strata hardness, leading to poor compaction rates reported by road construction clients.
Solução: Implementation of a cone crusher with automated Hydroset system and an advanced multideck screen within their closed circuit.
Resultados: Realtime CSS adjustment stabilized product shape (% cubicidade). Field data shows a consistent improvement of over 22% in flakiness index, eliminating product rejection and allowing a premium product price point.

[Planta de processamento de minério de ferro]

Desafio: Extreme abrasiveness of ore resulted in unsustainably high wear part costs in secondary crushing stages (850 hours—a ~40% increase—and monitoring enabled justintime changes during shift breaks.This reduced annual planned downtime related to liner changes by approximately 120 horas.

7\. CONSIDERAÇÕES COMERCIAIS

Industrial crushing and screening equipment pricing is tiered based on capacity throughput:
Nível I (1000 TPH): Fully customengineered systems with process simulation integration.

Optional features include advanced dust suppression systems fully integrated with water recycling plants,tiremounted mobile crawler systems,and centralized automated lubrication systems.Service packages are structured as Bronze (parts only), Silver (peças + scheduled maintenance),and Gold (fullsite service agreement including condition monitoring data analysis).Financing options include capital lease agreements tailoredto align payments with projected production revenue increases,and operating leases that include full service coverage.

8\. Perguntas frequentes

1º trimestre: Is your equipment compatible with our existing conveyor infrastructure?
A1: Our engineering team conducts presale audits.Crushers,telas,and feeders can be interfaced with existing conveyors provided load capacities match.We supply necessary transition chutes,support structures,and control system interfaces as part of the scope.

2º trimestre:Que nível de interrupção operacional devemos esperar durante a instalação?
A2:A detailed Site Implementation Plan minimizes disruption.For greenfield sites,there is no impact.For brownfield retrofits,a phased approach typically allows partial plant operation.Field data indicates full integration can be completed within a preagreed shutdown window of1421 daysfor most mediumcomplexity circuits

3º trimestre:Quais são os termos comerciais relativos à garantia?
A3:The standard warranty covers defects in materials/workmanshipfor12 monthsfrom commissioning.Extended structural warranties(upto60 monthson main frames)and performance guarantees(on throughputand power draw)are available subjectto agreed feed specifications

4º trimestre:What operator trainingis provided?
A4:A comprehensive program includes classroom instructionon principlesof operation,procedimentos de segurança,e solução de problemas básicos,followedby handson trainingat your site during commissioning.This typically spans5 daysfor lead operatorsand maintenance supervisors

Q5:What ongoing technical supportis available postpurchase?
A5:Dedicated technical supportis accessible24/7via phoneor our customer portal.Regional service engineers provide onsite support.Access todetailed parts manuals,schematic diagrams,and recommended spare parts listsis provided digitally at commissioning