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 crushing and screening circuit is often the bottleneck where profit is won or lost. Os desafios comuns incluem:
Tempo de inatividade não programado: Component failures in critical crushers or screeners halt entire production lines, custando milhares por hora em perda de produção e mão de obra.
Altos custos de manutenção: Frequent wear part replacement and extensive manual adjustments consume both budget and skilled technician hours.
Qualidade de produto inconsistente: Inefficient screening and improper crushing lead to offspec aggregate, resultando na rejeição do produto, custos de reprocessamento, e relacionamentos com clientes prejudicados.
Ineficiência Energética: Mais velho, nonoptimized equipment consumes excessive power per ton of material processed, impactando diretamente seus resultados financeiros.
Configuração Rígida: Fixed plants cannot adapt to changing feed material or final product requirements, limiting operational flexibility and contract opportunities.

What if your primary crushing station and screening deck could deliver not just throughput, mas desempenho previsível, menor custo por tonelada, and the agility to meet shifting market demands?

2. VISÃO GERAL DO PRODUTO

This product line encompasses a range of premium stationary and semistationary crushing and screening plants engineered for highvolume aggregate production, pré-trituração de mineração, e construção & reciclagem de demolição. O fluxo de trabalho operacional é projetado para, efficient material processing:

1. Alimentação Primária & Esmagamento: Dump trucks feed material into a rugged vibrating grizzly feeder which removes fines and directs oversize to a highcapacity jaw or gyratory crusher for initial size reduction.
2. Intermediate Conveying & Esmagamento: Crushed material is conveyed to secondary cone or impact crushers for further refinement, with metal detectors and tramp iron relief systems protecting downstream components.
3. Pré-triagem & Classificação: Material may be routed through a scalping screen before secondary crushing to improve efficiency.
4. Triagem Final & Estoque: The crushed aggregate is classified into precise specifications by multideck vibrating screens, with conveyors directing sorted material to designated stockpiles.

Escopo de aplicação: Ideal para extração em grande escala, hard rock mining primary circuits, e grandes projectos de infra-estruturas que exigem, agregados de alta qualidade (040mm+). Limitations include suitability primarily for fixed or semifixed installation sites; highly mobile contract crushing requires dedicated portable equipment.

3. RECURSOS PRINCIPAIS

Ajuste CSS do Hydroset | Base Técnica: Pistão hidráulico que suporta o eixo principal | Benefício Operacional: Configuração fechada (CSS) can be adjusted safely in under 60 segundos sem parar o britador, enabling rapid response to product gradation changes. | Impacto do ROI: Eliminates hours of manual shim adjustment downtime per change, increasing plant utilization by up to 7% anualmente.

Sistema de mídia de tela modular | Base Técnica: Interlocking polyurethane or rubber panels with tensioning rails | Benefício Operacional: Panels can be replaced by a twoperson crew in under 30 minutes per deck without specialized tools. | Impacto do ROI: Reduces screen deck maintenance downtime by over 50% compared to traditional woven wire cloth systems.

Automação de Plantas Baseada em PLC | Base Técnica: Controlador lógico programável centralizado com IHM touchscreen | Benefício Operacional: Monitors amp draw, temperaturas dos rolamentos, e taxas de alimentação; automatically regulates feeder speed and triggers alarms for preventative intervention. | Impacto do ROI: Evita falhas catastróficas; dados de campo mostram um típico 1520% redução de paradas não planejadas.

Tecnologia de britador de acionamento direto | Base Técnica: Crusher coupled directly to motor via Vbelts without gearboxes | Benefício Operacional: Maior eficiência de transmissão de energia (sobre 95%) and reduced mechanical complexity. | Impacto do ROI: Lowers energy consumption by up to 10% versus indirect drives and reduces potential failure points.

Nível 4 Final / Integração da Unidade de Energia Estágio V da UE | Base Técnica: Factoryintegrated, emissionscompliant diesel gensets or electric motor drives with soft starters | Benefício Operacional: Provides compliant power flexibility for remote sites or grids with limited capacity; soft starters reduce electrical network stress. | Impacto do ROI: Simplifies permitting; reduces peak current demand charges on electric installations.

Reinforced BoxSection Conveyor Frames | Base Técnica: Highstrength welded steel construction with internal stiffeners | Benefício Operacional: Withstands continuous heavyimpact loading without frame deflection or misalignment. | Impacto do ROI: Extends conveyor belt life by maintaining proper tracking; reduces structural maintenance over the plant's lifetime.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nosso esmagamento & Vantagem documentada da solução de triagem |
| : | : | : |
| Toneladas por hora (TPH) Disponibilidade | 8588% availability over a quarter >90% availability over a quarter +35% melhoria |
| Custo por tonelada (Peças de desgaste) USD $0.45 $0.55/ton processed USD $0.38 $0.42/ton processed Up to 20% redução |
| Consumo de energia (kWh/tonelada) ~0,85 1.1 kWh/ton ~0.75 0.95 kWh/ton Up to 15% melhoria |
| Tempo de mudança de mídia de tela (per deck) ~90 120 minutos <30 minutes Over 60% mais rápido |
| Tempo de ajuste CSS (Triturador de cone) ~60 90 minutos <2 minutes Over 95% mais rápido |

_Availability defined as (Scheduled Operating Time Unscheduled Downtime) / Scheduled Operating Time._

5.ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 400 TPH acima 1,500 Saída do produto final TPH.
Opções do britador primário: Britadores de mandíbulas (1,200abertura de alimentação mm x 830 mm) or Primary Gyratory Crushers (54" modelo).
Trituradores Secundários/Terciários: Britadores cônicos para serviços pesados ​​com múltiplas opções de câmaras.
Unidades de triagem: Highenergy tripledeck vibrating screens (up to 8m² screening area per deck).
Requisitos de energia: Full plant electric configuration typically requires a mains supply of 800kVA – 2MVA; integrated diesel genset options available.
Principais especificações de materiais: Manganese steel crusher jaws/liners (18% Mn); Revestimentos Hardox® em tremonhas e calhas; SKF/FAG class bearings throughout.
Dimensões Físicas (Pegada vegetal típica): Approximately L70m x W25m x H15m (varia significativamente com a configuração).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 25°C a +45°C; dust suppression system compliant with <10padrões de emissão mg/m³.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Desafio Uma pedreira necessária para aumentar a produção de lastro ferroviário (40mm+20mm) por 40% but faced space constraints preventing simple line duplication.
Solution Implementation of a singletrack mounted primary jaw crushing station feeding a dualprocess circuit with secondary cone crushers dedicated to different final products.
Results Achieved target throughput increase within the existing footprint; automated controls allowed quick switching between ballast production and aggregate chips (20milímetros), improving contract flexibility.

Urbano C&D Recycling Facility Upgrade

Challenge A recycling center processing concrete demolition waste experienced excessive wear from rebar contamination and inconsistent final product due to fluctuating feed composition.
Solution Installation of a heavyduty impact crusher with hydraulic apron adjustment for primary reduction paired with an aggressive doubledeck scalping screen fitted with abrasionresistant media.
Results Tramp metal removal efficiency improved by over 80%; consistent final aggregate quality met strict city specification for road base materials; wear part life increased by an average of 35%.

7. CONSIDERAÇÕES COMERCIAIS

Our luxury crushing equipment is positioned as a capital investment focused on longterm total cost of ownership reduction.

Pricing tiers are structured around core plant configuration:
Tier A Base Stationary Plant includes primary crusher feeder module basic screening tower stockpile conveyors starting at approximately USD $2 million
Tier B Advanced Automated Plant includes all Tier A features plus secondary/tertiary crushing modules PLC automation system advanced dust suppression
Tier C Custom Turnkey Solution fully engineered sitespecific solution including civil works design installation commissioning training

Optional Features Premium ceramic wear liners for highly abrasive applications remote monitoring telemetry package sound attenuation enclosures

Service Packages Annual Platinum Coverage comprehensive parts labor scheduled inspections Gold Coverage partsonly coverage with discounted labor rates

Financing Options Available through partnered financial institutions including operating leases capital leases longterm rentaltoown structures typically structured over 5year terms

8. Perguntas frequentes

Q What level of ground preparation is required for installation
A These are substantial permanent structures requiring professional civil engineering foundation design typically involving reinforced concrete piers footings Proper site preparation is critical for longterm alignment stability

Q How does this equipment integrate with our existing conveying system
A Our engineering team can design custom transfer chutes control system interfaces provided we receive detailed drawings of your current conveyor specifications Belt widths speeds heights must be matched

Q What is the expected operational lifespan of the main crusher frame
A With proper maintenance excluding wearable liners the main crusher body frames are designed for a minimum service life exceeding 25 years based on finite element analysis fatigue testing

Q Are operators provided training on the new control system
A Yes comprehensive onsite training for both operators maintenance technicians is included as standard during commissioning covering daily operation troubleshooting basic maintenance procedures

Q Can we source common wear parts like screen cloths locally
A While we recommend genuine parts for optimal performance our modular screen system uses standardized panel sizes that can accommodate certain thirdparty media Basic Vbelts bearings are also industrystandard items