1. PAINPOINT DRIVEN OPENING

Are you managing a highvolume aggregate operation where consistent output and plant uptime are critical to profitability? For plant managers and engineering contractors, a 250300tph stone crushing plant represents a major capital investment, yet common operational challenges can erode its expected return.

Inconsistent Throughput & Bottlenecks: Mismatched crusher stages or inefficient material flow can cause one section to idle while another is overloaded, preventing you from consistently achieving the rated 250300 tons per hour.
Unscheduled Downtime & High Maintenance Costs: Frequent component failures, especially in highwear areas like liners and bearings, lead to costly production halts and unpredictable repair expenses.
Final Product Quality Variability: Inability to precisely control particle size distribution and shape results in offspec material, reducing its market value or causing rejection by strict project specifications.
High Operational Complexity & Labor Costs: Plants requiring constant manual adjustment and monitoring increase labor overhead and raise the risk of human error affecting output.

The central question becomes: How do you specify a crushing plant that delivers not just on paper capacity, but on sustained, profitable operation with predictable costs?

2. PRODUCT OVERVIEW

This product is a complete, stationary 250300 TPH hard rock crushing and screening plant solution engineered for largescale quarrying, mining, and major infrastructure projects. It is designed as a multistage processing system to transform large (≤750mm) feed material into precisely graded final aggregates (e.g., 05mm, 510mm, 1020mm, 2031.5mm).

Operational Workflow:
1. Primary Crushing: Large dump trucks feed material into a robust primary jaw crusher for initial size reduction.
2. Intermediate Screening & Crushing: Prescreened material is routed to a secondary cone crusher for further reduction. Oversize material from screening is recirculated.
3. Tertiary/Fine Crushing: For highquality chip production, a tertiary cone crusher or impact crusher provides final shaping and size control.
4. Final Screening & Stockpiling: Multipledeck vibrating screens separate the crushed stone into specified grades, which are conveyed to designated stockpiles.

Application Scope & Limitations:
Scope: Ideal for highproduction granite, basalt, limestone, and other abrasive materials. Suited for permanent site installation with stable power supply.
Limitations: Not mobile or trailermounted; requires significant foundation work and civil construction. Feed material hardness must align with the selected crusher liner specifications.

3. CORE FEATURES

Modular Plant Design | Technical Basis: Preengineered, bolttogether structural modules | Operational Benefit: Reduces site installation time by up to 30% versus traditional weldedonsite designs | ROI Impact: Faster commissioning accelerates revenue generation and lowers labor costs.

Intelligent Process Control System | Technical Basis: Centralized PLC with SCADA interface and loadsharing algorithms | Operational Benefit: Automatically regulates feeder speeds and crusher settings for optimal chokefed operation | ROI Impact: Maintains target throughput while reducing energy consumption per ton by an estimated 812%.

HeavyDuty Component Selection | Technical Basis: Crushers with oversized main frames and forged alloy steel shafts; Class III conveyor idlers | Operational Benefit: Withstands peak load stresses and abrasive conditions, extending mean time between failures (MTBF) | ROI Impact: Lowers lifetime cost of ownership through reduced frequency of major overhauls.

Advanced Dust Suppression Integration | Technical Basis: Strategically placed spray nozzles with solenoid valves tied to conveyor start/stop signals | Operational Benefit: Effectively controls dust at transfer points without oversaturating material | ROI Impact: Ensures compliance with environmental regulations, avoiding fines and minimizing liner wear caused by dust.

Centralized Lube & Hydraulic Systems | Technical Basis: Automated grease banks and centralized hydraulic power units with filtration | Operational Benefit: Ensures critical bearings receive consistent lubrication; simplifies maintenance routines | ROI Impact: Prevents costly bearing seizures and reduces daily service time for operators.

HighCapacity Material Flow Design | Technical Basis: Wide conveyors (e.g., B1000B1200), deep crushing chambers, and generously sized hoppers | Operational Benefit: Eliminates material flow bottlenecks that cap production below the plant's theoretical capacity | ROI Impact: Enables consistent achievement of the full 250300tph design output.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Plant) | This 250300tph Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled Runtime)| ~85% 88% due to unplanned stops| Target >92% via robust design & controls| +4% to +7% more production time |
| Crusher Liner Life| Varies widely; often 750k tons in equivalent rock| +25% extended life potential |
| Power Consumption per Ton| Baseline (100%) reference figure| Optimized by load management systems| Up to 12% reduction |
| Installation & Commissioning Time| 810 weeks for full setup| Approximately 67 weeks with modular design| ~25% faster timetoproduction |

5. TECHNICAL SPECIFICATIONS

Design Capacity: 250 300 metric tons per hour (varies based on feed material hardness & size distribution).
Feed Size: Maximum lump size ≤750mm.
Primary Crusher: Jaw Crusher (e.g., PE900×1200 or equivalent), Power: 110132kW.
Secondary Crusher: SingleCylinder or MultiCylinder Hydraulic Cone Crusher, Power: 160220kW.
Tertiary Crusher: Fine Cone Crusher or Vertical Shaft Impact Crusher (optional), Power: 132180kW.
Screens: Multideck HeavyDuty Vibrating Screens (23 units), Total installed power ~30kW.
Conveyors: Belt width from B800 to B1200; Total installed conveyor power ~150kW.
Total Installed Power (Approx.): ~600 750 kW (dependent on final configuration).
Overall Plant Footprint (L×W): Approximately 85m × 65m (subject to layout customization).
Operating Temperature Range: 20°C to +45°C with appropriate lubricants and weather protection.
Key Structural Steel Specification： Main beams fabricated from Q345B steel.

6. APPLICATION SCENARIOS

Highway Construction Aggregate Supply

Challenge： A contractor needed guaranteed supply of >250tph of multiple specification aggregates (base course, chip seal) for a tightdeadline highway project，with strict flakiness index requirements.
Solution： Implementation of this threestage crushing plant featuring two cone crushers for superior particle shape control，with dedicated screening lines for each product。
Results： Plant consistently delivered over 280tph，producing over 1。2 million tons of inspec material within the project timeline。Product shape met all regulatory standards，eliminating qualityrelated delays。

LargeScale Granite Quarry Expansion

Challenge： An existing quarry’s aging plant suffered from low availability (<80%)and could not exceed200tph，capping business growth。Maintenance costs were escalating。
Solution： Replacement with this new250–300tphplant featuring heavyduty componentsand an intelligent control system。
Results： Field data shows firstyear availability reached93。5%，achieving an average annualized output of285tph。Maintenance expenditure per ton crushed decreased by an estimated18%。

7. COMMERCIAL CONSIDERATIONS

Our approach provides clarity in investment planning:

Equipment Pricing Tiers:
Standard Configuration： Includes primary jaw，secondary cone，screens，conveyors，and basic electrical controls。
Enhanced Configuration： Adds tertiary crushing stage，advanced PLC/SCADA control system，and upgraded dust suppression。
Turnkey Project： Includes full civil works design support，installation supervision，commissioning，and operator training。

Optional features include automated metal detection/removal systems，remote monitoring telematics packages，and extra stockpile conveyors。

Service packages are offered separately：
12month comprehensive warranty。
3year /5year scheduled inspectionand preventive maintenance plans。
24/7 remote technical supportwith guaranteed response times。

Financing options can be discussed through our partners including equipment leasing structuresor project financing tailoredto large capital expenditures。

FAQ

Q1： Is this plant compatible with our existing primary feeding system or secondary processing equipment？
A1： The plant is designed as a complete systemfor optimal performance。However engineering reviewscan be conductedto assess integration feasibilitywith specific existing equipment focusingon interface points like feed hopper dimensions conveyor heightsand electrical protocols。

Q2： What levelof operational staffis requiredto run thisplant？
A2： The automated control system simplifies operation typically requiring onecontrol room operatorand twofield personnelfor routine inspectionand minor adjustments。This representsa streamlined crewfor acapacityof this scale。

Q3： How does the pricing structurework？ Whatis typically excluded？
A3： Our quoted pricing covers all majormachinery steel structures motors drivesand local control panels。Exclusions generallyincludecivil foundation works site power connectionfromthe utility transformer freightto site customs duties（if applicable）andsite installation labor。

Q4： Whatisthe expected timelinefrom order placementto commissioning？
A4： Fora standard configuration lead timefor manufacturingis approximately16–20weeks。Site installationand commissioningrequirean additional6–8weeks assumingcivil worksare preparedin advance。Detailed project schedulesare providedupon engagement。

Q5： Can you provide specific projectionsfor wear part costsper ton？
A5 ： We provide estimated consumption ratesfor liners blow barsandscreen meshesbasedon your providedfeed material analysis Theseare presentedas costperton projectionsunder defined operating conditionsto aidin your operational budgeting。

Q6 ： Do you offerperformance guaranteesfortheplant？
A6 ： Yes we offerguaranteesfor rated throughputcapacity under agreed feed conditions final product gradationandelectrical power consumption Theseare formalizedin thecontract priorto purchase。

Q7 ： Whattrainingis providedfor our maintenance team？
A7 ： We include comprehensive trainingcovering daily operation routine maintenance procedures troubleshootingguidelinesforthe control systemand detailed review ofwear part replacement protocols Trainingoccurs bothat our facilityduring FAT（Factory Acceptance Test）andonsite during commissioning