germany exhibition 8th november 2010
Addressing Critical Operational Challenges in Heavy Machinery
Are escalating maintenance costs and unplanned downtime cutting into your operational margins? Industry data indicates that equipment failures in mineral processing and construction sectors result in an average of 120 hours of unscheduled downtime annually, with maintenance expenditures often exceeding 18% of total operating costs. These challenges are compounded by inconsistent output quality and rising energy consumption, directly impacting your bottom line.
How can you achieve a measurable reduction in lifecycle costs while ensuring consistent, high-volume production? What if you could implement a solution that addresses these core inefficiencies with proven technology? The innovations presented at the germany exhibition 8th november 2010 were specifically engineered to answer these pressing questions for commercial buyers and plant managers.
Product Overview: Advanced Industrial Processing System
The technology platform unveiled at the germany exhibition 8th november 2010 is a high-capacity, semi-autonomous crushing and screening system designed for rigorous mining and aggregate production environments. Its design focuses on operational resilience and cost-efficiency over extended service life.
Operational Workflow:
- Primary Feed Intake: Oversized raw material is received and pre-screened to remove non-processable debris.
- Multi-Stage Comminution: Material undergoes progressive reduction through a primary jaw crusher and secondary cone crusher.
- Intelligent Screening & Sorting: Crushed material is classified via a multi-deck vibrating screen.
- Automated Recirculation: Oversized particles are automatically redirected to the secondary crusher in a closed-loop circuit.
- Final Product Stockpiling: Correctly sized aggregate is conveyed to designated stockpiles.
Application Scope: Ideal for medium-to-large scale quarrying, alluvial mining, and recycled concrete aggregate production.
Limitations: Not suitable for highly abrasive metallic ores without specific liner configurations; requires a stable, prepared concrete foundation.
Core Features: Engineered for Performance and Payback
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Adaptive Crushing Chamber | Technical Basis: Hydro-pneumatic tramp release and clearing system | Operational Benefit: Prevents damage from uncrushable objects, automatically resetting without manual intervention | ROI Impact: Reduces component replacement costs by up to 30% and associated downtime by an estimated 45 hours per year
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Variable Frequency Drive (VFD) Crusher Motors | Technical Basis: Precision control of motor speed and torque | Operational Benefit: Enables real-time adjustment of product gradation and optimizes power draw based on feed load | ROI Impact: Field data shows a 22% reduction in energy consumption compared to fixed-speed drives
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Centralized Greasing & Condition Monitoring | Technical Basis: Automated lubricant delivery with flow sensors to all critical bearings | Operational Benefit: Your maintenance team receives real-time alerts for lubrication faults, ensuring bearing longevity | ROI Impact: Extends bearing service life by approximately 40%, minimizing unscheduled stoppages
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Modular Wear Liner System | Technical Basis: Segmented, reversible manganese steel liners secured with a bolted design | Operational Benefit Enables partial liner replacement in under 4 hours versus full-set changes | ROI Impact Cuts liner inventory costs by 25% and reduces planned maintenance man-hours by 60%
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Integrated Process Logic Controller (PLC) | Technical Basis: Siemens S7-1200 series with SCADA interface | Operational Benefit Provides your operators with real-time throughput data, power monitoring, and diagnostic fault codes | ROI Impact Facilitates data-driven decisions that increase overall equipment effectiveness (OEE) by an average of 15%
Competitive Advantages: Quantifiable Performance Gains
The following table compares the germany exhibition 8th november 2010 system against typical industry standards for similar capacity machinery.
| Performance Metric | Industry Standard | germany exhibition 8th november 2010 Solution | Advantage (% improvement) |
|---|---|---|---|
| Availability (Scheduled Operating Time) | 92% | 96.5% | +4.9% |
| Tonnage per Kilowatt-hour (kWh) | 48 t/kWh | 58 t/kWh | +20.8% |
| Mean Time Between Failures (MTBF) | 1,200 hours | 1,650 hours | +37.5% |
| Average Liner Life (Abrasive Rock) | 450,000 tons | 620,000 tons | +37.8% |
| Required Maintenance Man-Hours/Month | 80 hours | Fifty-five hours (55) hrs/mo.) | -31.3% |
Technical Specifications
- Capacity/Rating: Throughput capacity of 450 - 550 tonnes per hour, depending on material density and required reduction ratio.
- Power Requirements: Main crusher drive: 160 kW. Total connected load: 245 kW. Voltage:400V/50Hz (other configurations available).
- Material Specifications: Primary crusher jaws and cone mantles/concaves manufactured from ASMT A128 Grade Manganese Steel; Structural frame from S355JR steel.
- Physical Dimensions: Overall footprint: Length -12.5m; Width -3.8m; Height -4.2m.
- Environmental Operating Range: Designed for ambient temperatures from -20°C to +45°C. Dust protection rating of IP55.
Application Scenarios
#### Quarry Operations / Granite Aggregate Production
Challenge: A major quarry faced inconsistent product cubicity from their existing cone crusher, leading to high fines generation that reduced saleable product yield.
Solution: Implementation of the germany exhibition 8th november-optimized crushing circuit with its specialized chamber geometry and VFD control.
Results: Achieved a more consistent particle shape index (>90% cubicity), reduced fines generation by18%,and increased the yield of premium-priced products by22%.
#### Recycling / Construction & Demolition Waste
Challenge: A C&D recycling plant experienced frequent jams and excessive wear when processing reinforced concrete with residual rebar.
Solution: Deployment of the system featuring the Adaptive Crushing Chamber and Modular Wear Liner System.
Results: Eliminated downtime from tramp metal jams.Reported a35% extension in wear liner life despite abrasive conditions,and increased plant availability to96%.
Commercial Considerations
The capital investment for the germany exhibition eighth november two thousand ten equipment solution is structured across three primary tiers to match operational scale.
- Base Configuration (Tier I): Includes core crushing unit,VFD,and basic PLC controls.Pricing begins at €485,000.
- Enhanced Configuration (Tier II): Adds the automated greasing system,dust suppression kit,and advanced condition monitoring sensors.Pricing begins at €565,000.
- Turnkey Plant Integration (Tier III): Includes full electrical control house,surge feed hopper,and commissioning services.Pricing is project-specific.
Optional Features: Magnetic separator head pulley,wheel-mounted mobile configuration,custom screen media packages.
Service Packages: Comprehensive plans are available,ranging from annual inspection agreements to full-cost-per-tonne crushing contracts.Financing options include36-to60-month lease-to-own plans through our partnered financial institutions..jpg)
Frequently Asked Questions
- Is this equipment compatible with our existing primary feeding conveyor and downstream screening plant?
- Yes,the system is designed with industry-standard interfaces.CE-certified electrical control systems allow for straightforward integration into most existing plant infrastructure.Engineering support is provided during commissioning to ensure compatibility.
2.What level of operator training is required?.jpg)
- The intuitive SCADA interface requires minimal training for basic operation.A comprehensive two-day onsite training program is included with purchase,certifying your personnel on routine operation,fault diagnosis,and preventative maintenance procedures.
3.What are the lead times for delivery?
- Standard lead time for Tier IandII configurations is18 weeks from order confirmation.Tier III turnkey solutions typically require24-28 weeks based on scope.Tracked shipping containers are used for all international deliveries.
4.How does this solution impact our overall cost-per-tonne?
- Industry analysis demonstrates that the combined effectsof higher energy efficiency(22%),reduced liner costs(25%),and lower unplanned downtime(>40%) typically result in acost-per-tonne reductionof15-20% overa five-year period comparedto previous generationequipment.
5.Are performance guarantees offered?
- Yes,a performance guarantee covering throughput capacityand final product gradationis includedin the sales contract,basedon agreed-upon feed material testing.This ensures themachinery meetsyour specific production targets