1. PAINPOINT DRIVEN OPENING

Are you managing a quarry ballast operation where inconsistent product shape, excessive fines generation, and unplanned maintenance are eroding your margins? The production of highspecification railway ballast demands precision, yet many crushing plants struggle with these persistent challenges:
High Wear Costs: Abrasive granite, basalt, or gneiss rapidly degrades crusher liners and wear parts, leading to frequent stoppages and unpredictable consumables expenditure.
Poor Cubicity & Excessive Fines: Inefficient crushing action produces flaky or elongated aggregates and an oversupply of unsaleable fines (5mm), failing to meet stringent EN 13450 or AREMA gradation standards for angularity and durability.
Capacity Bottlenecks & Inefficiency: An illmatched primarytosecondary crushing circuit creates choke points, limiting total plant throughput and leaving potential revenue untapped.
High Operational Complexity: Equipment requiring constant adjustment and monitoring increases the skill burden on your team and raises the risk of offspec production runs.

What if your ballast crushing line could deliver consistent, inspec product with lower cost per tonne, extended maintenance intervals, and simplified control? The solution lies in selecting purposeengineered quarry ballast crushing equipment.

2. PRODUCT OVERVIEW

Our quarry ballast crushing equipment comprises heavyduty, stationary or semimobile crushing plants engineered specifically for highvolume production of railway ballast. The operational workflow is optimized for shape and yield:

1. Primary Reduction: Dumpfed material is initially reduced by a robust jaw crusher or gyratory crusher to a manageable size (typically <250mm).
2. Secondary Shape Crushing: The core of ballast production. Prescreened feed is directed to a cone crusher configured for aggressive interparticle comminution in a crowded chamber.
3. Final Sizing & Screening: Crushed aggregate is precisely screened on heavyduty vibrating screens. Onspec material (e.g., 31.563mm) is conveyed to stockpile; oversize is recirculated; undersize is diverted for byproduct sales or waste.

Application Scope: Ideal for hard rock (UCS >150 MPa) quarries supplying national rail networks, private industrial sidings, and construction projects requiring premium aggregate. This equipment is designed for continuous, hightonnage operation.

Limitations: Not suitable for soft or highly abrasive sedimentary rock without specific liner material review. Maximum feed size and ultimate capacity are determined by model selection.

3. CORE FEATURES

Hydroset CSS Adjustment | Technical Basis: Hydraulic cavity clearing and closedside setting control | Operational Benefit: Operators can adjust product gradation or clear blockages in under 60 seconds from a central location, minimizing downtime during changeovers or unexpected events. | ROI Impact: Reduces noncrushing time by up to 70% compared to manual adjustment systems, directly increasing annual throughput.

Liner Life Optimization System | Technical Basis: Automated wear compensation via constant hydraulic pressure on the crushing mantle | Operational Benefit: Maintains consistent product gradation as liners wear without manual intervention, ensuring continuous spec compliance over longer campaigns. | ROI Impact: Extracts maximum usable life from wear parts and reduces the frequency of liner changes, lowering both part costs and labor hours.

MultiLayer Crushing Chamber | Technical Basis: Engineered cavity profiles that promote interparticle crushing within a packed bed of material | Operational Benefit: Forces rockonrock breakage in the secondary/tertiary stage, producing superior particle cubicity while reducing direct metalonrock wear and fines generation. | ROI Impact: Increases saleable ballast yield by 815% per tonne of feed rock while decreasing liner abrasion costs.

HeavyDuty Vibrating Screen Integration | Technical Basis: HighG force screening decks with precisely sized apertures mounted on reinforced frames | Operational Benefit: Provides accurate final separation even under wet or sticky conditions, ensuring final product is free of undersized material as per rail authority specifications. | ROI Impact: Eliminates costly reprocessing of contaminated stockpiles and prevents rejection of loads at the point of delivery.

Centralized PLC Automation | Technical Basis: Programmable Logic Controller managing crusher load, feed rates, and interlocks with plant conveyors | Operational Benefit: Allows a single operator to monitor and optimize the entire circuit from a control room, regulating power draw for peak efficiency. | ROI Impact: Lowers personnel requirements per shift and reduces energy consumption per tonne by optimizing motor load.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Quarry Ballast Crushing Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Abrasive Rock)| 450550 kTonnes| 600750 kTonnes| +25% to +35% |
| Saleable Yield (>95% Cubicity)| ~82% of feed| 8892% of feed| +7% to +12% |
| Specific Energy Consumption| ~0.85 kWh/Tonne| ~0.72 kWh/Tonne| 15% |
| Average Unplanned Stoppages| 1218 hours/month| <6 hours/month| 60% |
| Gradation Consistency (Std Dev)| High variability within spec band| Tight control within spec band (field data shows ±3mm)| Improved process stability |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 to over 1,200 tonnes per hour (tph) of finished ballast product.
Power Requirements: Primary circuit from 90 kW; Secondary/Tertiary cone crushers from 160 kW up to 500 kW depending on model size.
Material Specifications: Engineered for maximum feed size up to 800mm; produces standard railway ballast fractions (e.g., 31.5/50mm, 40/70mm). Crusher mantles/bowls available in Manganese steel grades or optional premium alloys for extended life.
Physical Dimensions (Typical Secondary Station): Approx. Length: 10m x Width: 5m x Height: 5m (excludes feed hopper/discharge conveyors).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with optional heating/cooling systems for lubrication units.

6. APPLICATION SCENARIOS

National Rail Infrastructure Project | Challenge: A contractor required guaranteed daily tonnage of EN13450 Type A ballast under a fixedprice contract with severe penalties for delay. Their existing plant produced excessive fines (~22%) causing yield shortfalls.| Solution: Implementation of a tailored quarry ballast crushing circuit featuring our multilayer cone crusher technology paired with precise screening.| Results: Achieved consistent yield of saleable ballast at >90%, with fines generation reduced to below 14%. The project met all delivery schedules without penalty.

Granite Quarry Expansion | Challenge: A quarry operator needed to double ballast output without expanding their primary footprint or significantly increasing shift labor costs.| Solution: Installation of a highcapacity secondary/tertiary modular crushing station designed for direct conveyor integration with their existing primary crusher.| Results: Plant throughput increased by 115%. The automated system allowed operation with one additional operator per shift instead of two, improving output per labor hour by over 90%.

7. COMMERCIAL CONSIDERATIONS

Our quarry ballast crushing equipment is offered in three primary tiers:

1. Standard Duty Configuration: For operations <400 tph with robust base specifications.
2. HighCapacity Configuration: For outputs >600 tph featuring heavyduty components and advanced automation.
3. Modular/SkidMounted Configuration: For operations requiring future relocation or phased capital expenditure.

Optional features include dust suppression systems automated grease lubrication systems remote monitoring telematics packages

We offer comprehensive service packages including scheduled maintenance programs parts supply agreements

Financing options include capital purchase leasetoown agreements

8.FAQ

Q1 Is your equipment compatible with our existing primary jaw crusher
Yes our secondary stations are designed as standalone modules They can be integrated via conveyor systems

Q2 What impact will this have on our overall plant power consumption
Field data shows that due to optimized load management total specific energy consumption often decreases despite increased throughput

Q3 How long does commissioning typically take
For a complete turnkey station expect four weeks For modular integration into an existing line typical commissioning takes ten working days

Q4 What are the commercial terms
We require an order deposit upon contract signing Balance payment follows agreed milestones such as factory acceptance shipping confirmation

Q5 Do you provide operational training
Yes we include comprehensive training at your site during commissioning covering operation routine maintenance troubleshooting