1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges in primary crushing often stem from the crusher plant itself. Common pain points include:
Excessive Downtime for Maintenance: Frequent liner changes, bearing failures, and component wear can halt your entire operation for days, costing thousands per hour in lost production.
Inconsistent Output & Product Shape: Poorly sized feed or inefficient crushing chambers lead to uneven product gradation, causing bottlenecks in secondary circuits and reducing salable product yield.
High Operational Costs: Soaring energy consumption from inefficient drives and the constant need for replacement parts directly impact your bottom line.
Rigid Plant Configuration: Inflexible layouts that cannot adapt to changing feed material or final product specifications limit your ability to capitalize on new market opportunities.
Safety and Accessibility Concerns: Complex, unsafe maintenance procedures for critical components increase risk and extend service intervals.

What if your primary crushing station could deliver higher availability, predictable maintenance schedules, and a better return on capital? The solution lies not just in a crusher, but in a holistically engineered stone crusher plant.

2. PRODUCT OVERVIEW

Our stone crusher plant is a preengineered, stationary primary crushing solution designed for highvolume aggregate production in quarrying, mining, and largescale construction applications. It integrates a heavyduty jaw crusher or gyratory crusher with optimized feed and discharge systems into a single, cohesive unit.

Operational Workflow:
1. Controlled Feed: Dump trucks discharge into a rugged vibrating grizzly feeder, which scalps out fines and directs oversize material uniformly into the crusher.
2. Primary Reduction: The core crusher (Jaw or Gyratory) applies compressive force to reduce blasted rock to a predetermined top size.
3. Efficient Discharge: Crushed material is conveyed via heavyduty belt conveyors to the next stage of processing or stockpiling.

Application Scope: Ideal for hard rock (granite, basalt) and abrasive materials. Best suited for greenfield installations or major plant upgrades requiring capacities from 200 to over 1,500 tons per hour.

Limitations: Not designed as a portable/mobile unit; requires solid foundational support and planned infrastructure for utilities (power, dust suppression). For very sticky or highclay materials, preprocessing may be necessary.

3. CORE FEATURES

HEAVYDUTY VIBRATING GRIZZLY FEEDER | Technical Basis: Highstrength steel deck with adjustable grizzly bars & eccentric shaft vibrators | Operational Benefit: Removes fines prior to crushing, reduces crusher wear and power consumption by preventing chamber packing | ROI Impact: Extends wear part life by up to 20%, reduces uncrushable materialrelated stalls.

MODULAR PLANT STRUCTURE | Technical Basis: Bolttogether fabricated steel modules with precision alignment features | Operational Benefit: Significantly reduces site installation time and cost versus fieldwelded designs. Enables future reconfiguration or relocation. | ROI Impact: Cuts installation labor costs by an estimated 3040% and gets your plant operational weeks faster.

INTEGRATED DUST SUPPRESSION SYSTEM | Technical Basis: Strategically placed spray nozzles at transfer points with solenoid control tied to conveyor operation | Operational Benefit: Actively controls airborne particulate at source, ensuring compliance with environmental regulations and improving site working conditions. | ROI Impact: Mitigates risk of regulatory fines and reduces longterm cleanup costs.

HYDRAULIC ADJUSTMENT & CLEARING | Technical Basis: Crusher equipped with hydraulic systems for CSS adjustment and clearing tramp metal/uncrushables | Operational Benefit: Allows operators to adjust product size or clear a stalled chamber in minutes from a local station, without manual intervention. | ROI Impact: Minimizes downtime for routine adjustments by over 80% compared to manual shim systems.

CENTRALIZED GREASING & LUBRICATION | Technical Basis: Automated singlepoint or multipoint lubrication system servicing all major bearings | Operational Benefit: Ensures optimal bearing life through consistent lubrication intervals, reducing the frequency of manual greasing tasks. | ROI Impact: Lowers labor for routine maintenance and prevents costly premature bearing failures.

ROBUST WALKWAYS & MAINTENANCE PLATFORMS | Technical Basis: OSHAcompliant access platforms with nonslip grating around all service points | Operational Benefit: Provides safe, easy access for daily inspections, liner changeouts, and component servicing. | ROI Impact: Improves technician safety (reducing incident risk) and speeds up maintenance procedures by up to 25%.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Our Stone Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Mechanical Availability | 8590% | 9295%+ | +58% |
| Liner ChangeOut Time (Jaw) | 812 hours (crew dependent) | 46 hours (optimized procedure) | ~50% faster |
| Energy Consumption per Ton Crushed| Baseline (100%)| Reduced via efficient drive & feeder design| Up to 1015% lower |
| Installation & Commissioning Time| Fieldintensive (812 weeks)| Modular design (57 weeks)| ~3040% reduction |
| Wear Part Life (Mn18/22 Jaw Liners)| Subject to feed material| Extended via optimal chamber design & feed control| Documented 1525% improvement |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 TPH to 1,500+ TPH.
Primary Crusher Options: Jaw Crusher (900x1200mm to 1500x2000mm) or Primary Gyratory Crusher.
Feed Opening / Acceptable Feed Size: Up to 1200mm dependent on model selection.
Power Requirements: Total installed power typically between 250kW 600kW; supplied at customerspecified voltage (e.g., 6kV/11kV/400V).
Material Specifications: Main frame fabrications from S355JR structural steel; wear surfaces lined with AR400/500 abrasionresistant steel; highstrength bolts throughout.
Physical Dimensions (Example): Approx. Length: 25m x Width: 8m x Height: 10m (varies significantly with configuration).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dustprotected electrical components; optional heating/cooling packages available.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: A large granite quarry needed to increase primary capacity by 60% but had limited space for plant expansion and needed to maintain strict particulate matter (PM) emissions standards.
Solution: Implementation of a compact modular stone crusher plant featuring a large jaw crusher with an integrated highefficiency dust suppression system within the existing footprint.
Results: Achieved target throughput of 850 TPH while reducing PM emissions at the primary station by 70%. The modular design saved an estimated 9 weeks of installation time.

LargeScale Infrastructure Contract

Challenge: A contractor for a major highway project faced highly variable feed material (from soft limestone to hard abrasive gravel) requiring consistent 0150mm base material output under an aggressive timeline.
Solution: A tailored stone crusher plant with a robust grizzly feeder capable of handling variable loads paired with a hydraulically adjustable jaw crusher allowing quick CSS changes onsite.
Results: Maintained consistent product specification despite variable feed, enabling continuous supply to the project’s asphalt plants. The hydraulic adjustment feature reduced total adjustment downtime by approximately 120 hours over the project's lifespan.

7. COMMERCIAL CONSIDERATIONS

Our stone crusher plants are offered in three primary tiers:
Standard Duty Plant: For consistent limestone/medium abrasive rock up to 600 TPH.
Heavy Duty Plant: For hard rock (granite/basalt) applications up to 1 ,000 TPH featuring upgraded wear materials.
Extra Heavy Duty Plant: For maximum tonnage (>1 ,000 TPH), extreme abrasion resistance requirements including full AR lining packages.

Optional features include advanced automation controls(PLC/SCADA integration), secondary scalping decks on feeders , magnetic separators , extended conveyor systems ,and custom enclosure packages .

We offer comprehensive service agreements covering scheduled inspections ,wear part supply programs ,and remote technical support . Financing options including leasing structures are available through our partners .

FAQ

Q1 : Is this stone crusher plant compatible with my existing secondary / tertiary circuit ?
A1 : Yes . Our engineering team will review your current layout specifications . We design our plants' discharge height conveyor interfaces specifically around integration requirements .

Q2 : What is the expected operational impact on my overall energy consumption ?
A2 : Field data shows that our optimized drive train combined with efficient load distribution can reduce specific energy consumption per ton crushed typically between 10 % 15 % compared older less integrated setups .

Q3 : How does pricing work ? Is it based solely on capacity ?
A3 : Pricing is determined based on selected configuration tier required features . We provide detailed quotations outlining base equipment optional items installation support separately allowing you evaluate capital expenditure clearly .

Q4 : What are typical lead times from order placement commissioning ?
A4 : For standard configurations lead times range 20 30 weeks ex works depending current manufacturing schedule complexity . Detailed project timelines provided upon order confirmation .

Q5 : Who handles installation ? Do you provide supervision ?
A5 : We offer multiple options ranging supplying detailed erection drawings only full turnkey EPC services . Most clients opt our supervised installation package where our engineers oversee critical phases ensuring correct assembly commissioning .

Q6 : What warranty coverage provided ?
A6 : We offer standard months warranty against defects materials workmanship commencing commissioning date . Extended warranty packages available purchase covering major mechanical components longer periods .

Q7 Can this plant be relocated future ?
A7 Yes its modular bolt together construction facilitates disassembly relocation significantly more efficiently than traditional welded designs though this requires careful planning execution specialized contractor