1. ABERTURA ACIONADA POR PAINPOINT

Are you managing a private label aggregate or construction materials business where consistent product quality, tempo de atividade operacional, and perton cost control directly define your profitability? Sourcing crushing equipment often presents critical challenges:

Inconsistent Output & Brand Risk: Variable grain size and shape from unreliable equipment leads to offspec product, damaging your private label’s reputation and triggering rejections.
Unscheduled Downtime Costs: A primary crusher failure can idle an entire production line, costing thousands per hour in lost revenue, trabalho ocioso, and missed deliveries.
High Lifetime Operating Expenses: Frequent wear part changes, excessive energy consumption, and reactive maintenance on standard machines erode your margin over the 1015 year asset life.
Escalabilidade & Flexibility Gaps: Fixedconfiguration plants struggle to adapt to changing feed material or market demand for different aggregate products, limiting business agility.

How do you secure a crushing solution that operates as a reliable, efficient extension of your brand, not a constant source of operational risk and cost? The strategic answer lies in a purposebuilt Private Label Stone Crusher Plant.

2. VISÃO GERAL DO PRODUTO

UM Private Label Stone Crusher Plant is a complete, modular crushing and screening system manufactured to your exact brand specifications and performance requirements. It is not simply a rebadged standard model, but an engineered solution where every component is selected and integrated to optimize your specific feed material and output goals.

Fluxo de Trabalho Operacional:
1. Redução Primária: Raw feed material (por exemplo, 0700milímetros) is consistently fed into a robust primary jaw or impact crusher for initial size reduction.
2. Britagem Secundária/Terciária: Material is conveyed to secondary cone or impact crushers for further refinement, producing precisely shaped intermediate aggregates.
3. Precise Screening & Classificação: Multipledeck vibrating screens accurately separate crushed material into designated product fractions (por exemplo, 05milímetros, 510milímetros, 1020milímetros).
4. Estoque & Recirculação: O material sob especificação é transportado para estoques. Oversize material is automatically recirculated back into the circuit for recrushing, ensuring maximum yield and efficiency.

Escopo de aplicação & Limitações:
Escopo: Ideal for medium to largescale production of aggregates for readymix concrete, asfalto, base rodoviária, lastro ferroviário, e projetos de construção. Suited for limestone, granito, basalto, cascalho do rio, e concreto reciclado.
Limitações: Not designed for metallic ore processing or extremely abrasive/highsilica content materials without specific metallurgical configurations. Maximum feed size and hardness are defined during the engineering phase.

3. RECURSOS PRINCIPAIS

Custom Engineered Circuit Design | Base Técnica: Dynamic flow simulation & kinematic crusher modeling | Benefício Operacional: Optimal crusher selection and screen deck configuration ensures firstpass yield exceeds 85%, reducing recirculating load and wear | Impacto do ROI: Lower energy cost per ton and reduced wear part consumption by an estimated 1525%.
Unified PLC Control System with Branded HMI | Base Técnica: Centralized programmable logic controller with custom graphical interface | Benefício Operacional: Your operators manage the entire plant from a single, intuitive panel displaying your logo; enables precise calibration for different product recipes | Impacto do ROI: Reduces startup/washout time by up to 30% and minimizes operator error.
HeavyDuty Modular Chassis | Base Técnica: Análise de Elementos Finitos (FEA) optimized steel structures with highstress reinforcements | Benefício Operacional: Provides exceptional stability under full load vibration, extending structural life and maintaining precise alignment of conveyors and crushers | Impacto do ROI: Elimina reparos estruturais dispendiosos; enables future relocation or expansion with minimal downtime.
Premium Component Standardization | Base Técnica: Strategic specification of globally sourced bearings, motores, driveshafts & hydraulic components from Tier1 suppliers | Benefício Operacional: Aumenta o tempo médio entre falhas (MTBF); simplifies maintenance inventory with common parts across multiple crushers/screens | Impacto do ROI: Reduces parts stocking costs by ~20% and improves maintenance efficiency.
Supressão de poeira integrada & Redução de ruído | Base Técnica: Encapsulated transfer points with spray nozzles & acoustic dampening panels | Benefício Operacional: Maintains compliance with increasingly strict site environmental regulations without requiring extensive external retrofit | Impacto do ROI: Avoids project delays or fines; improves community relations for urban/periurban sites.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | Private Label Stone Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Consistência do Produto (Shape Index) | Variável; dependent on feed fluctuation & estado de desgaste. | Consistent cubicity maintained via optimized cavity design & controlled feed rates. | Até 40% more uniform product based on field particle shape analysis. |
| Disponibilidade Operacional (Horário agendado) | ~8590%, factoring in unscheduled mechanical stops. | Targets >94%, achieved via overspec components & predictive maintenance design. | 59% increase in productive hours annually. |
| Consumo de energia (kWh/tonelada) | Fixed speed drives; less optimized crushing chamber geometry.| Unidades de frequência variável (VFD) on feeders/conveyors & efficiencytuned crushers.| Documented reductions of 1018% in specific energy consumption. |
| Vida útil da peça (Manganese Tons/Set)| Standard manganese steel grades; generic cavity profiles.| Applicationspecific manganese alloys & computerdesigned liner profiles.| Aumentos de 2035% dependendo da abrasividade do material. |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 150 para 600+ toneladas por hora (TPH), depending on final circuit design.
Requisitos de energia: Total installed power typically between 350kW 800kW; supplied for 50Hz or 60Hz operation at voltages up to the customer specification.
Especificações de materiais: Primary frame constructed from S355JR structural steel; wear surfaces utilize Hardox® or equivalent abrasionresistant steel; Crusher jaws/mantles in premium Mn18Cr2 or Mn22Cr2 alloy.
Dimensões Físicas: Modular design allows transport within standard shipping containers; assembled plant footprint is customized per layout but designed for compactness.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; dust emission levels can be configured to meet sub10 mg/Nm³ standards.

6. CENÁRIOS DE APLICAÇÃO

Private Label Aggregate Producer for National Retail Chain

Desafio: A supplier needed to produce six distinct decorative landscape aggregates under its own brand for a major retailer but faced high reject rates due to inconsistent sizing from aged equipment.
Solução: Implementation of a tailored private label stone crusher plant featuring a tertiary cone crusher circuit with specialized screening decks calibrated for each product SKU.
Resultados: Product consistency achieved >98% compliance with retailer specifications on all lines within one month of commissioning.

Municipal Road Base Production Contractor

Desafio: A contractor operating multiple public works projects required mobile crushing capacity but could not afford the downtime associated with moving and repermitting separate units at each site.
Solução: A semimobile private label plant on a trailerized chassis was deployed as their dedicated asset across all city contracts over three years.
Resultados: Reduced mobilization time between sites by over twothirds due to preapproved permits based on standardized environmental controls.

7 CONSIDERAÇÕES COMERCIAIS

Our private label stone crusher plants are offered under transparent pricing tiers based on capacity complexity:

1\. Base Plant Tier (Up To ~250 TPH): Includes primary jaw secondary impactor basic screening module core conveyors PLC control system Warranty starts at [Price Range Estimate]
2\. HighCapacity Tier (~251–500 TPH): Adds tertiary crushing stage advanced multideck screening dust suppression package heavyduty feeders
3\. Custom Integrated Tier (500+ TPH): Fully engineered circuit including automated product switching advanced telemetry remote monitoring capabilities

Recursos opcionais incluem:
Sistemas automatizados de lubrificação com graxa
Tramp metal detection/autoreject systems
Pacotes de geração de energia a bordo
Extended warranty/service plans covering parts labor

Opções de financiamento:
We work with international export credit agencies project finance partners offer flexible leasetoown structures typical terms ranging months

8 Perguntas frequentes

Q1 How do you ensure the plant will perform with our specific rock type?
A1 Our engineering process begins with detailed analysis of your feed material samples including crushability work index abrasiveness We use this data calibrate our simulation models provide guaranteed performance metrics before fabrication

Q2 What level branding customization possible?
A2 Full exterior branding control panel graphics documentation provided You also receive technical documentation branded manuals spare parts lists under your company name

Q3 How does implementation affect our current production schedule?
A4 Plants are preassembled tested at our facility prior shipment minimizing onsite commissioning time typically weeks not months minimizing disruption

Q4 What ongoing technical support available?
A4 We offer tiered service packages from basic remote troubleshooting comprehensive annual maintenance contracts including regular inspections wear part optimization recommendations

Q5 Are these plants suitable regions strict environmental noise regulations?
A5 Yes they can specified include comprehensive enclosures baghouse filter systems sound dampening packages designed meet stringent EU US standards

Q6 Can plant expanded later increased capacity?
A6 The modular design inherently allows addition extra crushing stages larger screens extended conveyor systems planned during initial design phase facilitates costeffective future expansion