1. PAINPOINT DRIVEN OPENING

Are unpredictable breakdowns and inconsistent output crippling your aggregate production schedule? For plant managers and engineering contractors, the true cost of a stone crusher extends far beyond its purchase price. Key operational challenges include:
Unscheduled Downtime: Bearing failures or component wear can halt an entire production line, costing thousands per hour in lost output and idle labor.
High Wear Part Consumption: Frequent replacement of liners, jaws, or blow bars under abrasive conditions directly erodes operational margins.
Inconsistent Product Gradation: Poorly calibrated or worn crushers produce offspec material, leading to product rejection, recrushing costs, and dissatisfied customers.
Excessive Energy Consumption: Inefficient crushing chambers and drives can make electricity a topthree operating expense.
Rigid Configuration Limitations: Fixed plants struggle to adapt to changing feed materials or required product mixes, limiting operational flexibility.

How do you select equipment that directly addresses these profitability killers? The solution lies in a stone crusher machine engineered not just for peak performance, but for sustained, costeffective operation under realworld conditions.

2. PRODUCT OVERVIEW

This product line encompasses heavyduty primary jaw crushers and secondary cone crushers designed for stationary aggregate production plants. The operational workflow is engineered for reliability:
1. Primary Reduction: Large feed material (up to specified inlet size) is compressed and fractured between a fixed and oscillating jaw plate.
2. Material Flow: Crushed discharge from the primary unit is conveyed to a secondary cone crusher via a closedloop system.
3. Secondary/ Tertiary Crushing: The cone crusher further reduces material via compression between a mantle and concave liner within an optimized crushing chamber.
4. Gradation Control: Final product size is precisely determined by the closedside setting (CSS) of the crusher.

Application Scope: Ideal for processing granite, basalt, limestone, and other abrasive aggregates in fixedplant quarrying and largescale mining operations.
Limitations: Not designed for portable/skidmounted applications, highly contaminated or metallic feed materials without prior screening, or ultrafine grinding (sub10mm) as a sole unit without additional tertiary stages.

3. CORE FEATURES

Patented Crushing Chamber Geometry | Technical Basis: Computermodeled kinematics & dynamic finite element analysis | Operational Benefit: Ensures consistent interparticle compression crushing, reducing slabby product and improving overall particle shape index by up to 15%. | ROI Impact: Highervalue end product with less waste, reduced need for reprocessing.

Integrated Hydraulic Setting Adjustment | Technical Basis: Centralized hydraulic ram system for main shaft positioning | Operational Benefit: Allows operators to adjust the crusher’s closedside setting (CSS) in under 2 minutes for precise gradation control without stopping the feed. | ROI Impact: Minimizes downtime during product changeovers, enabling rapid response to market demands.

HeavyDuty Forged Main Shaft & Roller Bearing Assembly | Technical Basis: Highalloy steel forging with L10rated spherical roller bearings | Operational Benefit: Provides exceptional radial and axial load capacity to handle peak crushing forces and tramp metal events without catastrophic failure. | ROI Impact: Extends major component lifecycles by over 30%, preventing costly unscheduled repairs.

Advanced Wear Part Metallurgy | Technical Basis: Manganese steel alloy with proprietary heat treatment (Q&T Process) | Operational Benefit: Liners develop a workhardened surface layer in operation, significantly increasing service life in highly abrasive applications. | ROI Impact: Reduces costperton for wear parts by an average of 1822%, based on field data from granite quarries.

PLCBased Automation & Monitoring System | Technical Basis: Industrial programmable logic controller with pressure & temperature sensors | Operational Benefit: Provides realtime alerts for abnormal conditions (e.g., high bearing temp, low hydraulic pressure) and allows for automated startup/shutdown sequences. | ROI Impact: Protects the machine from damage and allows one operator to manage multiple processes, optimizing labor costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Stone Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Average Liner Life (Abrasive Rock) | 450,000 tons | 550,000 tons | +22% |
| Energy Consumption per Ton Output| 0.85 kWh/t | 0.72 kWh/t |15% |
| Mean Time Between Failure (MTBF)| ~1,200 hours| ~1,650 hours| +37% |
| Gradation Consistency (Std Dev)| ±12% of target| ±8% of target| +33% more consistent |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 200 800 TPH (depending on model & feed material)
Power Requirements: Primary Crusher: 90160 kW; Secondary Crusher: 132250 kW (400V/50Hz or customizable)
Material Specifications: Highstrength welded steel frame (S355J2), ASTM A128 Grade B3/B4 manganese steel liners.
Physical Dimensions (Example Model): Primary Jaw Unit Footprint: ~6m L x 3m W; Secondary Cone Unit Footprint: ~4m L x 3m W.
Feed Opening Sizes: Primary Jaw Options: 900x600mm up to 1200x1000mm.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with optional kits available for extreme dust or humidity conditions.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: A major quarry needed to increase finished aggregate output by 40% but was constrained by frequent cone crusher mantle changes every 6 weeks causing excessive planned downtime.
Solution: Implementation of our secondary cone crusher with advanced metallurgy liners and hydraulic setting adjustment system.
Results:Liner service life extended to an average of 9 weeks (+50%), while CSS adjustment time reduced from ~45 minutes to under two minutes per changeover. This contributed to an overall plant availability increase of over 11%.

Limestone Processing Plant Modernization

Challenge:A cement plant’s raw material preparation circuit suffered from high energy costs (~28% of OPEX) and inconsistent feed size to the kiln due to an aging primary jaw crusher.
Solution:A new highefficiency primary jaw crusher was installed featuring optimized chamber geometry and a directdrive system replacing Vbelts.
Results:The new stone crusher machine reduced specific energy consumption by approximately17%, while improved fragmentation consistency stabilized kiln feed rates,increasing thermal efficiency by an estimated3%.

7.COMMERCIAL CONSIDERATIONS

Our stone crushers are offered in three primary tiers:
1.Standard Duty Series: For consistent,fineabrasion materials like limestone.Covers core reliability features.Base pricing typically ranges from $150k$350k depending on capacity
2.Heavy Duty Series: For mixed/highly abrasive feeds like granite/basalt.Includes upgraded metallurgy,bearings,and protection systems.Pricing typically ranges from $300k$600k
3.Modular Plant Solutions: Fully integrated crushing/screening stations on modular skids.Priced as turnkey systems starting at $750k

Optional features include automated lubrication systems,dust suppression packages,and remote telemetry connectivity.Service packages range from basic preventive maintenance plans(PM kits+inspections)to comprehensive fullcoverage contracts including all wear parts.Financing options include capital lease agreements with fixed monthly payments,and rentaltoown structures managed through our partner network

8.FAQ

Q:What level of foundation preparation is required comparedto other heavyduty stonecrushers?
A:The design incorporatesa reinforced base frame that distributes dynamic loads effectively.Field data shows our units require standard reinforced concrete foundations comparableto industry norms;detailed civil drawings are providedwith purchase

Q.How does your automation system integratewith existing plant PLCs?
A.Thecrusher'sPLCis equippedwith standard industrial communication protocols(Profibus,Ethernet/IP).Itcan be configuredto operateas a standalone unitor asa slave devicewithin your wider plant control networkfor centralized monitoring

Q.Whatis your policyon wear part warranties?
A.Wear parts(manganese liners)are coveredbya performance warrantyagainst premature failure due tomaterial defects.Thiswarrantyis proratedbasedon actual tonnage producedand requiresproperoperational documentation

Q.Can we trialthe equipmentwith our specificmaterial before committingto apurchase?
A.We operate several regional test centerswhereyou can submit bulk samplesfor processingand receivea detailed performance reportincludinggradationanalysisand predictedwear rates

Q.Whatisthe typicallead timefrom orderto commissioning?
A.For standard modelsin our HeavyDutySeries lead times average1620weeks.Complex modular solutionsrequire2228weeks.Alltimelinesinclude factoryassembly testingand documentationpackaging