Chinese Sand Gravel Mining Contract Manufacturer
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Растущие эксплуатационные расходы и непредсказуемые простои снижают рентабельность песка и гравия? Managing a modern aggregate operation presents distinct challenges that standard equipment often fails to address. Рассмотрим эти общие, дорогостоящие сценарии:
Высокая одежда & Затраты на техническое обслуживание: Abrasive silica and gravel rapidly degrade standard components, что приводит к частым, unscheduled shutdowns for liner changes, pump rebuilds, and conveyor belt replacements.
Непостоянное качество конечного продукта: Fluctuations in feed material cause offspec product—fines content too high or particle distribution out of grade—resulting in rejected loads and lost revenue.
Неэффективная вода & Sludge Management: Ineffective washing and clarification systems waste process water, create environmental compliance hurdles, and lose valuable fines to settling ponds.
Низкая общая эффективность установки: Bottlenecks at crushing, скрининг, or material handling stages limit total throughput, preventing you from capitalizing on highdemand periods.
What if your key processing equipment was engineered from the ground up to confront these specific abrasion, классификация, and reliability challenges? The solution lies in partnering with a specialized contract manufacturer for your core sand gravel mining equipment.
2. ОБЗОР ПРОДУКТА
This content details a comprehensive line of stationary and modular sand washing, классификация, and dewatering equipment manufactured under contract for sand and gravel mining operations. As your contract manufacturer, we engineer and build the core machinery that transforms raw feed into specification aggregate.
Операционный рабочий процесс:
1. Кормить & Распределение: Crushed material is evenly distributed into the washing system.
2. Потертость & Освобождение: Rotating paddles or screws scrub particles to break down clay clots and liberate fines from coarse aggregate.
3. Hydraulic Classification: Precise water flow rates separate particles by size and specific gravity in settling tanks or hydrocyclones.
4. Mechanical Dewatering: Screws or vibratory decks remove excess water from fine and coarse products to meet shipping moisture specifications.
5. Взыскание штрафов & Управление водными ресурсами: Integrated cyclones and thickeners capture ultrafine particles for byproduct sale while clarifying water for recirculation.
Область применения: Ideal for virgin aggregate processing, crushed stone rewashing, and construction/demolition material recycling. Primary limitations include maximum feed size (typically ≤1”) and the requirement for a consistent water supply; dry processing solutions are configured separately.
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
Polyurethane Wear Components | Техническая основа: Advanced elastomer casting with high tear strength | Операционная выгода: Outlasts standard rubber liners by 300500% in abrasive silica applications | Воздействие на рентабельность инвестиций: Reduces component changeout frequency by over 60%, lowering parts inventory costs and maintenance labor hours.
Частотно-регулируемый привод (ЧРП) Контроль | Техническая основа: Precision AC motor speed regulation via programmable logic controller (ПЛК) | Операционная выгода: Operators can instantly adjust screw speed or slurry density in response to feed changes | Воздействие на рентабельность инвестиций: Maintains onspec product yield, reducing waste by an average of 15% as per field data.
Unified Rinse Water System | Техническая основа: Pressurized manifold distributing clarified water across final rinse screens | Операционная выгода: Ensures thorough cleansing of final product without increasing fresh water consumption | Воздействие на рентабельность инвестиций: Lowers fresh water makeup requirements by up to 30%, снижение затрат на перекачку и воздействия на окружающую среду.
BoltTogether Modular Chassis | Техническая основа: Fabricated structural steel design with predrilled connection points | Операционная выгода: Enables rapid site relocation or plant reconfiguration with minimal cutting/welding | Воздействие на рентабельность инвестиций: Cuts redeployment time by 50%, allowing faster response to shifting deposit locations.
Integrated Cyclone Cluster Packages | Техническая основа: Bank of smalldiameter hydrocyclones for highG force separation | Операционная выгода: Recovers ultrafine sand (100400 сетка) from waste streams for sale as a byproduct | Воздействие на рентабельность инвестиций: Adds a new revenue stream; typical plants report payback on this module in under 12 месяцы.
Централизованная система смазки | Техническая основа: Automated manifold delivering grease to all critical bearings on timed intervals | Операционная выгода: Eliminates manual greasing points in hardtoreach locations, обеспечение оптимального срока службы подшипников | Воздействие на рентабельность инвестиций: Documented reduction in bearingrelated failures by over 80%, protecting against catastrophic downtime.
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Стандартный эталон отрасли | Our Sand Gravel Mining Contract Solution | Документированное преимущество |
| : | : | : | : |
| Liner Life in Abrasive Silica Sand | 750 1,000 часы работы | 3,000 4,000 часы работы (Полиуретан) | +300% улучшение |
| Fresh Water Consumption per Ton Processed| ~100 gallons/ton (открытый цикл) | ~70 gallons/ton (замкнутая система) | 30% снижение |
| Fine Material Recovery (92% recovery to product stream (with cyclone pack) | +27 процентные пункты |
| Среднее время между отказами (среднее время безотказной работы) Критические диски| ~2000 часов| >4,500 часы (with VFD & централизованная смазка)| +125% улучшение |
| OnSpec Product Consistency (Градация)| ±5% variation from target sieve| ±2% variation from target sieve (with VFD control)| Дисперсия уменьшена на 60% |
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Модельный ряд Вместимость: От 50 TPH pilot/test units to highvolume 450 TPH production plants.
Требования к питанию: Plantdependent; typical single module ranges from 75 HP в 250 HP total connected load at 480V/3Phase/60Hz (other voltages configurable).
Характеристики материала: Primary wear components constructed from ASTMrated abrasionresistant steel (>400 БХН), cast polyurethane (>95A Durometer), and ceramic linings in ultrahigh wear zones.
Физические размеры (Typical Single Screw Washer): Длина: ~35’, Ширина: ~10’, Высота: ~15’. Modular design allows for stacking or sidebyside placement.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +50°С. (4°F to 122°F). Dust enclosures and heated bearing options available for extreme environments.
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Коммерческий производитель песка – Средний Запад США
Испытание: A producer faced significant profit loss due to high silt/clay content contaminating final concrete sand products, leading to frequent customer rejections.
Решение: Implementation of a highcapacity fine material washer with an integrated attrition cell and cyclonebased fines recovery system.
Результаты: Reduced deleterious materials content from >6% к <0.5%. The recovered fines were sold as a filler material. Overall plant profitability increased by an estimated $12/ton on washed concrete sand.
Alluvial Gravel Pit Operator – Western Canada
Испытание: Seasonal freezing conditions caused severe downtime during spring thaw due to sedimentladen process water that could not be effectively clarified for recirculation.
Решение: Contract manufacturing of a modular washing plant featuring a highcapacity deep cone thickener for rapid solids settling and sludge densification.
Результаты: Achieved closedloop water recycling within 48 hours of seasonal startup versus the previous twoweek average. Reduced fresh water procurement costs by over $45,000 annually and ensured consistent earlyseason production.
7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Our contract manufacturing model provides flexibility tailored to your operational scale:
Ценовые уровни: В зависимости от мощности (ТПХ) and complexity—from standard singlescrew washer packages (300 ТПХ).
Дополнительные функции / Обновления: Common upgrades include automated polymer dosing systems for fines flocculation , телематические пакеты удаленного мониторинга , стартовые комплекты запасных частей ,and custom discharge chute configurations .
Пакеты услуг: Choose from annual preventative maintenance inspections , guaranteed parts availability programs with defined SLAs ,and ondemand technical support .
Варианты финансирования: We work with thirdparty financial institutions who specialize in heavy equipment financing . Solutions include capital leases , операционная аренда ,and leasetoown structures designed around project cash flow .
8. Часто задаваемые вопросы
1 квартал: Is your equipment compatible with our existing crushing plant setup?
Да . Our systems are designed as both standalone plants or as bolton modules . We require your existing plant’s discharge conveyor height , скорость подачи ,and available power specifications . Our engineering team will provide detailed interface drawings .
2 квартал:Каково ожидаемое влияние на общую производительность нашего завода??
By eliminating bottlenecks at the washing stage , most operations see an increase in total usable output . Field data shows plants often realize a net gain of between1020 %in salable tons per hour due reduced waste material handling .
Q3:What are typical lead timesfor contractmanufactured equipment?
Lead times varyby complexity . For standard designs we maintain partial inventoryof key components ;typical delivery is1418 weeksfrom order approval . Custom engineered solutions require2226 weeksfor full fabrication assembly testing .
Q4:What commercial terms do you offer?
Standard commercial terms involvea progress payment schedule tiedto major manufacturing milestones :30 %upon order40 %upon major fabrication completion25 %upon completionof factory acceptance testing5 %upon shipment .
Q5:What levelof operator trainingis provided?
We include comprehensive onsite trainingfor both operationsand maintenance crewsas partof commissioning This covers normal startup/shutdown procedures routine maintenance troubleshooting guidesand safety protocols Documentation includesfull electrical schematics parts manuals lubrication schedules
Q6:Canyour systems handle recycled concreteor asphalt millings(РЭП)?
Yes but this requires specific configuration Heavily soiledor contaminated C&D debris often needs enhanced attrition scrubbing We recommend providinga sampleof your feedstockfor pilot testingto determine the optimal machine parameters
Q7:Doyou provide performance guarantees?
We provide mechanical performance guaranteescovering workmanship materials Additionally we can establish process performance criteria basedon pilot test resultsor agreedupon feed specifications These are detailed within the commercial proposal