1. PAINPOINT DRIVEN OPENING

Managing quarry sites in Lagos presents distinct operational and logistical hurdles that directly impact profitability and export compliance. Are you contending with inconsistent aggregate quality leading to rejected export shipments? Are logistics bottlenecks and port delays causing missed delivery windows and contractual penalties? Is the high cost of inland transportation from your quarry sites in Lagos to Apapa or Tin Can ports eroding your margin on every ton? Furthermore, do manual sizing and sorting processes create unpredictable yield, wasting valuable resource and limiting your ability to fulfill large, standardized export orders? These challenges are compounded by equipment downtime in a harsh environment, where every hour of lost production delays revenue. The central question for exporters is this: how can you establish a reliable, highvolume supply chain from your quarry face to the port that consistently meets international aggregate specifications?

2. PRODUCT OVERVIEW: MODULAR CRUSHING & SCREENING PLANTS FOR EXPORTREADY AGGREGATE

For quarry operators targeting export markets from Lagos, a stationary or semimobile crushing and screening plant is the core solution. This integrated system transforms blasted rock into precisely graded, washed, and stockpiled aggregates ready for direct loading onto export vessels.

The operational workflow is engineered for export efficiency:
1. Primary Crushing: Large feed material from the quarry face is reduced by a robust jaw crusher.
2. Secondary/Tertiary Crushing & Screening: Cone crushers further refine the material, which is simultaneously screened via vibrating screens to separate sizes.
3. Aggregate Washing: Sand particles and fine aggregates are processed through a screw classifier or sand plant to remove silt and impurities, meeting strict cleanliness standards for concrete aggregate.
4. Final Sorting & Stockpiling: Correctly sized and washed material is conveyed to dedicated stockpiles via radial stackers, creating segregated product bays for efficient loadout.

Application Scope: Ideal for mediumtolarge scale granite or limestone quarry sites in Lagos producing aggregates (10mm, 12mm, 20mm, sharp sand) for construction and concrete markets. Limitations: Requires stable site preparation and grid or heavyduty generator power; not suitable for highly mobile, smallscale operations.

3. CORE FEATURES

HighCapacity Primary Jaw Crusher | Technical Basis: Deep crushing chamber & optimized nip angle | Operational Benefit: Handles large feed stone from Lagos quarries with fewer blockages, enabling consistent throughput for highvolume export orders | ROI Impact: Reduces idle time at the primary stage by up to 30%, directly increasing tonsperhour output.

Integrated Aggregate Washing System | Technical Basis: Counterflow screw classifier with water recycling settlement ponds | Operational Benefit: Removes clay, silt, and dust to achieve below 3% silt content, ensuring exported material passes standard ASTM/EN tests | ROI Impact: Eliminates cost of rejected shipments and preserves premium product pricing for washed aggregates.

HeavyDuty Vibrating Screens with Polyurethane Decks | Technical Basis: Multideck screening surfaces with high Gforce vibration | Operational Benefit: Provides precise separation of up to four aggregate fractions simultaneously with high wear resistance in abrasive granite applications | ROI Impact: Increases saleable product yield by minimizing missized material; polyurethane decks last 300% longer than wire mesh in silicarich stone.

Centralized PLC Automation System | Technical Basis: Programmable Logic Controller with touchscreen HMI | Operational Benefit: Allows operators to monitor crusher load, conveyor speeds, and screen efficiency from a single cabin, enabling rapid adjustment to maintain spec | ROI Impact: Reduces manpower requirements per shift by 23 personnel while improving process consistency.

Modular Conveyor & Stockpiling Design | Technical Basis: Radial stackers with variable discharge height | Operational Benefit: Creates organized, highcapacity stockpiles for multiple product grades directly beside loadout area or trucks | ROI Impact: Cuts loadout time by over 50% by eliminating doublehandling and ensuring fast truck turnover.

CorrosionResistant Component Specification | Technical Basis: Marinegrade paint systems & stainless steel fittings on critical components | Operational Benefit: Withstands the highhumidity and saline air environment common to coastal quarry sites in Lagos | ROI Impact: Lowers longterm maintenance costs and protects asset resale value.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Lagos Region) | Our Modular Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Total Yield of InSpec Export Material| 6575% of feed mass due to poor sorting/washing loss| 8592% of feed mass through precision circuits| +20% average yield increase |
| Downtime for Wear Part ChangeOut| 812 hours for screen deck replacement| <4 hours with quickchange deck tensioning system| 60% maintenance window |
| Power Consumption per Ton Processed| Varies widely; often inefficient diesel genset use| Optimized drive motors & energyefficient crusher geometry| Documented 1520% reduction per ton |
| OnSite Manpower Required per Shift| 810 personnel for operation & manual sorting| 56 personnel with centralized control & automation| 40% labor dependency |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Configurable from 150 TPH to 400 TPH (Tons Per Hour) of finished aggregate.
Power Requirements: Primary plant operates on 300 kVA – 800 kVA grid connection or equivalent heavyduty diesel generator set (500 kVA – 1250 kVA).
Material Specifications: Engineered for processing hard abrasive granite (PSV >50) & limestone; Crusher jaws & concaves manufactured from Mn18Cr2 or TIC insert alloys.
Physical Dimensions (Typical Setup): Primary crushing module footprint approx. 12m x 5m; Full plant layout including stockpile area requires ~80m x 60m prepared site.
Environmental Operating Range: Designed for ambient temperatures of 25°C – 45°C; humidity up to 95%; dust suppression system standard; electrical components rated IP65.

6. APPLICATION SCENARIOS

Granite Aggregate Exporter Challenge near Ikorodu

Challenge:A quarry producing granite aggregates faced frequent shipment rejections at the port due to excessive silt content (>5%) in their sharp sand fraction.
Solution:A turnkey modular plant was installed featuring an emphasized washing circuit with a dual screw sand plant.
Results:Silt content consistently reduced below 2%. The exporter secured a longterm contract with a readymix concrete supplier in West Africa based on guaranteed quality specs.

LargeScale Limestone Operation Targeting Multiple Grades

Challenge:A major operator needed to efficiently produce four separate limestone grades (base course, drainage aggregate, concrete aggregate) simultaneously but was constrained by slow manual sorting.
Solution:A threestage crushing plant with tertiary cone crushers and two tripledeck finishing screens was implemented.
Results:The plant achieved simultaneous production of all four grades at 280 TPH total throughput. Loadout efficiency improved as trucks could be filled directly from specific stockpiles without waiting.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Solutions are configured projectspecifically.
EntryLevel: Basic twostage crushing & screening setup starts at a competitive investment point suitable for expanding existing operations.
MidRange: Most common configuration includes tertiary crusher, washing system,and basic automation.
Premium ExportReady: Full circuit with advanced PLC control,sand optimization plant,and comprehensive dust suppression.
Optional Features: Onboard diesel power modules,magnetic separatorsfor metal contamination,camerabased rock size monitoring systems,customized conveyor lengthsfor specific site layouts.
Service Packages: Choose from annual preventive maintenance plans offering guaranteed response times,scheduled wear part inspections,and priority access to technical support.Field data shows plants under service contracts experience 35% less unplanned downtime.
Financing Options: Flexible arrangements available including leasetoown structures over3660 monthsand tailored equipment financingto help manage capital expenditure against confirmed export contracts.

8. FAQ

1.Q:What if my current quarry site has limited space?
A.Modular plants are designedwith flexibility.Semimobile skidmounted units can be considered,and our engineering team can provide site layout optimization services specifictoLagos quarry constraints.

2.Q.How does this equipment handle Nigeria's frequent power fluctuations?
A.Plants can be specifiedwith softstart systemsand protective relays.We strongly recommend pairingwitha dedicated heavyduty generator set sizedfor100%plant loadas aprimaryor backup sourceforuninterrupted export production schedules.

3.Q:What is the typical lead timefrom orderto commissioningat our quarry siteinLagos?
A.For standard configurations,the lead timeis typically1622 weeksexworks,followedby46 weeksfor shipping,customs clearance,and supervised installation& commissioningby our engineers.Delays relatedtoport congestionare factoredinto project planning.

4.Q.Can you guarantee the final aggregate gradation?
A.The equipmentis engineeredtodeliver precise gradation curves when correctly configuredfor your feed material.We conduct presale material testingand provide performance guaranteesbasedon agreed feed sizeand hardness parameters.Postinstallation tuningis part ofthe commissioning processto ensure spec compliance

5.Q.What trainingis providedforour localoperatorsand maintenance crew?
A.Comprehensive trainingis mandatory.We provide both classroom instructionon theoryandsafety,and extensive handson trainingatthe commissioned site.Training manualsare suppliedin Englishwith key operational steps translated.Local technicianscan be certifiedthrougha structured program

6.Q.Are spare parts readily availablein Nigeria?
A.We maintaina strategic inventoryof critical wear parts(liners,screen meshes,bearings)ina dedicated Lagos warehouse.Common parts are available within24 hours.Specialized components have aguaranteedairfreight delivery timelinefrom our global hubs

7.Q.How doesthe pricing modelwork—isthisa full turnkey quote?
A.We provide detailedcapital expenditure(CAPEX)quotesthat include all majormachinery,support steelwork,belt conveyors,basic electricals,and commissioning.The quote clearly delineates clientsupplied items suchasthe prepared base,civil works,fencing,final power connectionto genset/grid,and loadout equipmentfor accurate budgeting