ODM کوٽائي گيٽ کرشنگ سامان ٺاهيندڙ
1. PAINPOINT driven اوپننگ
ڇا توهان هڪ ڪوارري آپريشن کي منظم ڪري رهيا آهيو جتي بيلسٽ جي پيداوار هڪ نازڪ اڃان مشڪلاتي رڪاوٽ آهي? چئلينج مخصوص ۽ قيمتي آهن. Inconsistent feed material leads to frequent jaw crusher bridging and choking, غير منصوبابندي بند ٿيڻ جو سبب آهي جيڪو گم ٿيل پيداوار ۾ هزارين في ڪلاڪ خرچ ڪري سگهي ٿو. The final product shape is often subpar, with excessive flaky or elongated particles that fail to meet stringent rail or construction specifications, پراڊڪٽ رد ڪرڻ جي ڪري. ان کان سواء, high wear rates on manganese steel components from abrasive granite or basalt result in unpredictable maintenance costs and parts inventory headaches. Your plant’s energy consumption per ton of finished ballast may be eroding profit margins. Are you questioning how to achieve consistent, specificationgrade product with higher uptime, گھٽ قيمت, ۽ آسان سار سنڀال? The solution lies in selecting the correct ODM quarry ballast crushing equipment.
2. پيداوار جو جائزو
ھن پراڊڪٽ لائن ۾ ڳري ڊيوٽي شامل آھي, stationary and semimobile crushing plants engineered specifically for highvolume quarry ballast production. هڪ ODM طور (اصل ڊيزائن ٺاهيندڙ) equipment maker, we provide tailored primary, ثانوي, and tertiary crushing solutions built to your precise feedstock and output specifications.
The operational workflow for optimal ballast production is:
1. ابتدائي گھٽتائي: Scalped feed material is reduced by a robust jaw crusher or gyratory crusher to a manageable size.
2. ثانوي ڪرشنگ & شڪل ڏيڻ: ballast پيداوار جي دل, where a cone crusher—configured for aggressive interparticle comminution—further reduces size and begins cubical shaping.
3. ٽئين درجي جي اصلاح & ماپڻ: عمودي شافٽ متاثر ڪندڙ (هرڪو) or a finely tuned cone crusher in closed circuit with screens delivers the final cubical product shape and precise gradation.
4. Efficient Screening & ٻيهر گردش: Multideck screens accurately separate oversize, ختم ٿيل پيداوار, ۽ ڏنڊ, with oversize efficiently recirculated.
Application scope includes dedicated ballast production for railway construction/maintenance and highspecification construction aggregate. Key limitations involve feed size constraints specific to the primary crusher inlet and maximum throughput defined by the circuit design.
3. بنيادي خاصيتون
ترقي يافته چيمبر جاميٽري | ٽيڪنيڪل بنياد: Optimized crushing cavity profiles and kinematics | آپريشنل فائدا: Promotes interparticle crushing for superior cubical shape while reducing wear on liners | ROI اثر: Higher saleable product yield (فيلڊ ڊيٽا تائين ڏيکاري ٿو 15% reduction in waste flaky material) and extended wear part life.
خودڪار سيٽنگ جو ضابطو (ASR) سسٽم | ٽيڪنيڪل بنياد: Hydraulic adjustment and monitoring of crusher closedside setting (سي ايس ايس) حقيقي وقت ۾ | آپريشنل فائدا: Maintains consistent product gradation automatically, compensating for wear without manual intervention | ROI اثر: Eliminates gradationrelated stoppages and ensures continuous spec compliance.
Hybrid Manganese Steel Liners | ٽيڪنيڪل بنياد: Proprietary alloy composition and heat treatment process | آپريشنل فائدا: Provides enhanced workhardening capability in abrasive ballast crushing applications | ROI اثر: دستاويز ٿيل 2030% longer service life compared to standard Mn18 liners, reducing parts cost per ton.
سڌو ڊرائيو کولہو ٽرانسميشن | ٽيڪنيڪل بنياد: Elimination of Vbelts through direct coupling of motor to crusher | آپريشنل فائدا: پاور ٽرانسميشن جي ڪارڪردگي کي وڌائي ٿو (to ~99%) ۽ سار سنڀال جي پوائنٽن کي گھٽائي ٿو | ROI اثر: Lower energy consumption per ton crushed and reduced risk of downtime from belt failure/slippage.
Integrated Plant Automation & تشخيص | ٽيڪنيڪل بنياد: Centralized PLC with IoTenabled sensors for load, دٻاءُ, گرمي پد, and vibration | آپريشنل فائدا: Provides operators with realtime health status alerts and predictive maintenance triggers | ROI اثر: Enables planned maintenance windows, preventing catastrophic failures that cause extended downtime.
ماڊلر فريم جي تعمير | ٽيڪنيڪل بنياد: Heavyduty fabricated steel sections with precision alignment features | آپريشنل فائدا: سائيٽ جي تنصيب کي آسان بڻائي ٿو, منتقلي, and future plant reconfiguration | ROI اثر: Reduces foundation costs and installation time by up to 25%, improving project ROI.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري معيار | Our ODM Quarry Ballast Crushing Solution | دستاويزي فائدو |
| : | : | : | : |
| پراڊڪٽ فلڪينس انڊيڪس (ايف آئي) | عام طور تي >20% for conventional circuits | مسلسل 93% via ASR & predictive monitoring| 35 سيڪڙو پوائنٽ ۾ اضافو |
| لباس جي قيمت في ٽون (ابراھيندڙ پٿر)| $0.85 $1.10 آمريڪي ڊالر/ٽن| $0.60 $0.75 آمريڪي ڊالر/ٽن| ~25% reduction in consumable cost|
| توانائي جو واھپو (kWh/tonne)| مختلف; بيس لائين = 100% index| جي انڊيڪس 8590 via direct drive & efficient flow| 1015% improvement in efficiency |
Based on annual operational data from comparable installations.
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 150 ختم ڪرڻ 800 tonnes per hour of finished 40mm/+28mm specification ballast.
پرائمري کولہو جا اختيار: جبڑے کي ٽوڙڻ وارا (900 x 600mm up to 1500 x 1300mm feed opening) or Primary Gyratory units.
ثانوي / ثانوي Crushers: Highperformance cone crushers (200kW to 500kW drive power) or VSI units for final shaping.
بجلي جي گهرج: Total installed plant power from 400kW to 1200kW+, supplied at 6kV or medium voltage as required.
اهم مواد جي وضاحت: S355JR ساخت واري اسٽيل مان ٺهيل; Liners in proprietary ZGMn22Cr or equivalent highabrasion steel.
جسماني طول و عرض: Modular designs adaptable to site layout; typical footprint for a 300tph plant is approximately 40m L x 25m W x 15m H.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dust suppression systems integrated; شور جي اخراج سان مطابقت <85 ڊي بي(اي) at periphery.
6. درخواست جا منظر
Heavy Rail Ballast Production – Granite Quarry
چيلنج: A national rail operator’s primary quarry was unable to consistently meet the strict PSD (ذرات جي ماپ جي تقسيم) and FI limits for premium track ballast using its older multistage crushing plant, facing high recirculation loads (~35%) and excessive liner wear.
حل: Implementation of a tailored ODM threestage plant featuring an ASRequipped secondary cone crusher set for aggressive reduction followed by a tertiary VSI for final shaping.
نتيجا: Flakiness Index reduced from ~23% to a consistent 12%. ٻوٽن جي ذريعي وڌو ويو 22% due to lowered recirculation load. Wear part lifecycle extended by an average of 28%, confirming projected costperton savings.
Port Infrastructure Project – Basalt Aggregate
چيلنج: A major port expansion required over 2 million tonnes of highspecification armor stone and bedding layer ballast within an aggressive timeline. The contractor’s mobile fleet could not achieve the required shape or volume efficiently.
حل: Deployment of a semimobile ODM primary jaw and secondary cone crushing station onsite, fed directly by drill & blast shot rock.
نتيجا: The dedicated circuit produced specification material at a steady rate of over550 tph directly into stockpiles for loading onto barges.The project secured a twomonth schedule buffer due toreliable output,and eliminated offsite hauling costsfor preliminarycrushing
7.تجارتي خيالات
Our ODM quarryballastsolutions are offeredin tiered configurations:
بنيادي ٺاھ جوڙ جو درجو(Core Plant): Includesprimary feeder,کولڻ وارا,اسڪرين,and basic PLC controls.Priced as acapital investmentwith defined lead timefor engineeredtoorderunits.Financingthrough partner institutionsis availablefor qualified buyers
ڪارڪردگي جو درجو(بنياد +): Adds theAutomated SettingRegulation(ASR)systemadvancedhybridlinerson keycrushersand enhanceddust suppression.Financedvia leasetoownor equipmentloan agreements
Full OptimizationTier(Turnkey): Incorporatesfull IoTpredictiveanalyticspackageextendedwarrantycoverageon drivesand bearingsand optionalonsitecommissioning&operatortraining service.Package pricingavailablewithtailoredservicelevelagreements(SLAs)
Optional featuresinclude dieseloverelectricdrive modulesfor fully mobile setupsand soundattenuation enclosuresfor urbanproximate quarries
Service packagesrangefrom annualinspectionsand parts supplyto full remote monitoringand guaranteedavailabilitycontractswith performancebased terms
We providecommercial flexibilitythroughoutright purchasefinancing leasesor paypertonproduction contractsfor largerscale partnerships
FAQ
Q1:What if my feed material varies significantly between hard abrasive graniteand softer limestone?
A1:The corecrushingchambersand automation systemsare designedto handle variance.Hydraulic adjustmentallowsontheflycompensationfor different materialsensuringconsistent outputgradation.We willspecifythe optimalliner profileand eccentricthrow duringdesignbasedonyour predictedfeed blend
Q2:What levelof operator skillis requiredto run thisballastspecificplant?
A2:The integratedautomationsignificantlysimplifiesoperation.The centralcontrolsystemprovidesclearoperationalguidance.Most dailyfunctionsare monitoredautomaticallyreducingthe burdenon operators.We providecomprehensive trainingfocusingon systemlogicratherthan manualadjustment
Q3:What isthe typicalimplementationtimelinefrom orderto commissioning?
A3.Fora standardengineeredODMstationaryplant leadtimeis typically2024weeks.Semimobile skidbased solutionscan shipin1618weeks.Timelinesare confirmedafterthe initialsite reviewand geotechnicaldata exchange
Q4.How doesthe predictive diagnosticsystemactuallywork toprevent failures?
A4.Its monitorsvibrationtrendsin bearingslubricationpressuretemperature differentialsand motorcurrentdraw.Deviationsfrom establishedhealthybaselines triggeralerts allowingmaintenanceto be scheduledbeforea functional failureoccurs.This targetsunplanneddowntimewhichis themost costlydisruption
Q5.Are spareparts readilyavailablegiven thisis specializedODMequipment?
A5.All criticalwear parts(jaw platescone mantlesetc.)are manufacturedto internationalstandards(SAE J4 )with documentedchemicalcomposition.Consumableinventoryis heldat regionalhubs anda guaranteed48hourdispatchserviceappliesfor criticalpath itemsunder serviceagreements
