complete crushing systems

Addressing Your Most Critical Crushing Operation Challenges

Are your production targets consistently undermined by systemic inefficiencies? In aggregate production and mineral processing, the limitations of a patchwork plant configuration directly impact your bottom line. Industry data indicates that operations relying on mismatched or aging equipment face specific, quantifiable challenges:

• Unplanned Downtime: Crusher blockages, conveyor misalignment, and screen failures can halt your entire process. Every hour of unscheduled downtime can cost operations between $10,000 and $50,000 in lost production and labor.
• Inconsistent Product Gradation: Fluctuations in final product size lead to out-of-spec material, causing load rejections and reducing your premium product yield. This can diminish the value of your output by 15-25%.
• High Operational Costs: Inefficient power draw from non-optimized motors, combined with high wear part consumption and excessive manual sorting labor, erodes profit margins.
• Scalability Limitations: Is your current setup unable to adapt to changing feed material or increased throughput demands without a complete and costly structural overhaul?

What if you could implement a solution where every component is engineered to work in concert from the start? A system designed not just to crush, but to optimize your entire material flow for maximum tonnage and reliability.

Product Overview: High-Capacity Stationary Complete Crushing Systems

Our complete crushing systems are engineered as single-source, stationary plants for high-volume aggregate mining and mineral processing applications. These are not simply collections of individual machines; they are fully integrated circuits designed for continuous operation.

Operational Workflow:

1. Primary Receiving & Crushing: Run-of-mine or quarry-run material is fed into a robust primary jaw crusher for initial size reduction.
2. Secondary & Tertiary Reduction: Pre-screened material is routed through cone crushers for further refinement, ensuring precise intermediate product sizing.
3. Material Screening & Classification: Multi-deck vibrating screens accurately separate the crushed material into specified product fractions.
4. Stockpiling & Re-circulation: On-spec material is conveyed to stockpiles, while oversize is automatically returned to the appropriate crusher via closed-circuit conveyors.

Application Scope: Ideal for large-scale production of aggregates (limestone, granite, trap rock), as well as base metal and industrial mineral processing circuits.

Limitations: These systems are designed as permanent or semi-permanent installations. For operations requiring frequent site relocation, mobile crushing solutions may be more appropriate.

Core Features: Engineered for Performance and Profitability

• Unified Process Intelligence | Technical Basis: Centralized PLC with SCADA integration | Operational Benefit: Your operators can monitor and adjust the entire circuit—from feed rate to crusher settings—from a single control station, reducing response time to operational variables. | ROI Impact: Field data shows a 20% reduction in operator-related process deviations, leading to more consistent output and lower re-circulation loads.

• Optimized Feed System | Technical Basis: Stepped grizzly feeder with integrated pre-screening | Operational Benefit: Removes fines prior to primary crushing and ensures a consistent, non-segregated feed to the jaw crusher. | ROI Impact: Reduces unnecessary wear on the primary crusher liners and can increase primary circuit capacity by up to 12%, directly lowering cost-per-ton.

• Heavy-Duty Conveyor Circuit | Technical Basis: Computer-modeled transfer points and impact-resistant idlers | Operational Benefit: Minimizes material spillage and belt wear at critical transfer points, which are common sources of maintenance intervention. | ROI Impact: Decreases conveyor maintenance labor and parts replacement costs by an average of 30% annually.

• Advanced Crushing Chamber Designs | Technical Basis: Liner profile optimization using dynamic simulation software | Operational Benefit: Achieves a more efficient nip angle and crushing action, resulting in a superior particle shape index and higher throughput for the same power input. | ROI Impact: Improved product cubicity increases market value, while higher throughput lowers energy cost per ton.

• Integrated Dust Suppression | Technical Basis: Automated spray system with solenoid valves at each emission point | Operational Benefit: Actively controls dust generation at crusher outlets and transfer points, supporting compliance with site health and safety regulations. | ROI Impact: Mitigates risk of regulatory fines and reduces cleanup costs, while protecting downstream equipment from abrasive dust ingress.

Competitive Advantages

Performance Metric	Industry Standard	Our Complete Crushing Systems Solution	Advantage
System Availability	85-89%	94%+ (Contractually Guaranteed)	>5% Improvement
Power Consumption (kWh/ton)	Varies by rock type	Up to 10% reduction through system optimization	10% Improvement
Wear Part Life (Primary Liners)	Standard Manganese Steel	Proprietary alloy liners with optimized profiles	15-20% Improvement
Product Yield (In-Spec Material)	Highly variable; ~80-85% average post-tuning	Consistent >92% yield from commissioning	~10% Improvement

Technical Specifications

• Capacity/Rating: Configurable from 500 to 2,500 tonnes per hour.
• Power Requirements: Primary plant motors typically require a total connected power of 800 - 2,200 kW; supplied via main distribution panel with soft-start systems on major drives.
• Material Specifications: Fabricated from high-tensile steel (ASTM A36 / A572 Grade 50); Crusher wear parts in T700 Mangalloy or equivalent; Abrasion-resistant steel liners in hoppers and chutes (AR400/500).
• Physical Dimensions: System footprint is project-specific; typical primary/secondary plants require an area of approximately 60m x 40m.
• Environmental Operating Range: Designed for ambient temperatures from -25°C to +45°C. Optional packages available for extreme arctic or desert conditions.

Application Scenarios

#### Large Granite Quarry Operation | Challenge: A national aggregate producer faced inconsistent product gradation from their aging three-stage plant, leading to high re-circulating loads (over 35%) that strained crushers and increased energy costs. Frequent belt mistracking caused daily downtime for adjustments. Solution Implementation involved replacing the legacy setup with a complete crushing system featuring an intelligent PLC-controlled circuit with load-management technology on all conveyors and crushers. Results Within six months of operation, re-circulating load was reduced to under 20%, increasing net usable throughput by 18%. Belt-related stoppages were eliminated entirely.

#### Iron Ore Processing Plant Upgrade Challenge An existing plant needed higher throughput but was constrained by its original layout. Bottlenecks at screening towers limited capacity expansion without a prohibitively expensive structural rebuild.Solution A modular complete crushing system was engineered off-site and installed during a planned seasonal shutdown. The new design optimized transfer heights and incorporated larger-screen media.Solution The plant achieved its target of a 25% capacity increase without major civil works. The pre-commissioned modules reduced on-site installation time by eight weeks versus traditional methods.

Commercial Considerations

Equipment Pricing Tiers:

• Base System: Includes primary jaw crusher, secondary cone crusher(s), triple-deck screen, conveyors, walkways, and central control station.
• Enhanced System: Base plus integrated dust suppression system automated greasing systems on all bearings advanced wear monitoring sensors
• **Turn-Key System Enhanced package plus civil engineering support erection & commissioning services operator training

Optional Features:

On-board weighing instrumentation remote monitoring telematics package sound attenuation enclosures secondary fuel power generation compatibility

Service Packages:

Proactive maintenance plans provide scheduled inspections parts discounts guaranteed lead times on critical spares Performance-based contracts link service fees directly to achieving availability targets offering shared risk reward models Financing options include capital expenditure loans operating lease agreements pay-per-tonnage structures aligning payments with production revenue

Frequently Asked Questions

1. How does this system integrate with our existing downstream processing equipment?
Our engineering team conducts a full review of your current plant layout Our complete crushing systems are designed with standardized discharge heights conveyor widths interfaces ensuring compatibility with existing flotation mills or washing plants Minimal site adaptation is typically required

2 What level of operational disruption should we expect during implementation?
We develop detailed phased implementation plan Pre-assembled modules significantly reduce on-site construction time For greenfield projects we manage entire timeline For brownfield upgrades work is sequenced parallel production where possible major tie-ins scheduled during planned outages

3 Are these performance guarantees backed by contractual agreements?
Yes Key metrics including minimum throughput product gradation envelope overall system availability are formalized within sales agreement These are based on pilot testing ore characterization providing both parties clear measurable benchmarks

4 What technical support is available after commissioning?
Support includes dedicated account manager remote diagnostics via secure data link access regional service technicians comprehensive documentation parts warehouse network We offer tiered support contracts match your internal maintenance capabilities risk tolerance

5 Can this system be expanded if our production requirements increase future?
The modular design allows strategic expansion Upgrades like additional tertiary crushing circuit finer screening decks can be incorporated initial design considers future tie-in points structural loads minimizing obsolescence protecting long-term investment