mini stone crushing plant

Addressing the Core Challenges of Small-Scale Aggregate Production

Are you managing small to medium-sized projects where the cost and logistics of a full-scale crushing operation are prohibitive? The challenges of sourcing consistent, high-quality aggregate for construction, road base, or site development can significantly impact your project timelines and bottom line. Consider these common operational pain points:

• High Mobilization Costs: Transporting large stationary crushers or relying on off-site crushing for small-batch requirements consumes budget and introduces scheduling dependencies.
• Inflexible Feed Material Processing: Single-crusher setups often struggle with varying feed sizes and material hardness, leading to blockages, excessive wear, and inconsistent output gradation.
• Significant Quarry or Site Footprint: Traditional plants require substantial space for setup, conveyors, and stockpiling, which is not always available on constrained urban or remote project sites.
• Labor-Intensive Operation: Manual feeding and monitoring tie up skilled personnel, increasing operational costs and introducing variability in final product quality.

What if your operation could achieve the precise product specification you need, on-site and on-demand, with a system designed for rapid deployment and simplified operation? The solution lies in a properly engineered mini stone crushing plant.

Product Overview: The Compact Aggregate Solution

A modern mini stone crushing plant is a compact, semi-mobile or trailer-mounted system designed for the specific needs of small-batch production. It integrates primary crushing and secondary screening functions into a single, space-efficient footprint. The operational workflow is streamlined for efficiency:

1. Controlled Feeding: Material is loaded via excavator or wheel loader into a integrated hopper, often with a vibrating feeder to regulate flow to the crusher.
2. Primary Size Reduction: A single crusher unit—typically a jaw crusher for hard abrasives or an impact crusher for softer materials like limestone—processes the feed to a primary crushed size.
3. Product Classification: Crushed material is conveyed to an integrated screen deck that separates it into specified aggregate sizes (e.g., 0-5mm, 5-10mm, 10-20mm).
4. Stockpiling & Recirculation: On-spec material is conveyed to stockpiles while oversize material is automatically recirculated back into the crusher for further processing.

Application Scope & Limitations:
This equipment is engineered for contractors handling demolition waste recycling, small quarry operations, road construction sub-base production, and site development projects requiring up to 150 tons per hour. It is not intended as a direct replacement for large-scale, fixed-plant primary crushing circuits processing several hundred tons per hour of virgin hard rock.

Core Features: Engineered for Performance & Profitability

The design of our mini stone crushing plant focuses on delivering maximum operational utility with minimal overhead.

• Integrated Feeder & Pre-Screen | Technical Basis: Grizzly bar section with vibrating mechanism | Operational Benefit: Removes fines from the feed stream before crushing, increasing capacity and reducing crusher wear | ROI Impact: Reduces liner replacement costs by up to 15% and improves overall throughput

• High-Efficiency Jaw Crusher | Technical Basis: Deep crushing chamber with aggressive nip angle | Operational Benefit: Ensures effective size reduction of hard rock and reinforced concrete with minimal risk of bridging | ROI Impact: Higher yield of usable product per ton of raw feed; extends operational periods between maintenance

• Onboard Conveying & Screening | Technical Basis: Folding side conveyors and a multi-deck vibrating screen | Operational Benefit: Eliminates the need for separate screening units and additional conveyors; enables closed-circuit operation for precise product control | ROI Impact: Cuts mobilization time by over 50% and reduces equipment rental costs

• Hydraulic Adjustment & Setting | Technical Basis: Centralized hydraulic power pack for crusher gap adjustment and component actuation | Operational Benefit: Allows operators to change product size quickly and safely from ground level without manual intervention | ROI Impact: Minimizes downtime during product changeover; enhances operator safety

• Electric Power Option | Technical Basis: Direct electric drive connection or onboard diesel generator set | Operational Benefit: Provides flexibility for sites with grid power, significantly lowering fuel costs and noise emissions | ROI Impact: Field data shows up to 40% lower operating costs compared to pure diesel-hydraulic systems over a 1,000-hour period

• Compact Transport Configuration | Technical Basis: Pivot-and-fold chassis design meeting road transport regulations | Operational Benefit: Enables quick relocation between project sites without requiring special transport permits in most cases | ROI Impact: Reduces logistical planning time and transportation expenses

Competitive Advantages

The following table quantifies the performance improvements our mini stone crushing plant delivers against common industry benchmarks for equipment in this class.

Performance Metric	Industry Standard (Trailer-Mounted Crushers)	Our Mini Stone Crushing Plant Solution	Advantage
Average Setup Time (from arrival)	4-6 hours with auxiliary equipment	< 2 hours with self-contained system	>50% faster
Fuel Consumption (Tier 4 Final Diesel)	~12-15 L/hour under load	8-10 L/hour with optimized hydraulics	~30% improvement
Ratio of Usable Product to Total Feed*	~75-80% (without pre-screen)	>90% (with integrated pre-screen)	>12% more saleable material
Required Operating Personnel	Typically 2-3 personnel	Efficiently operated by 1-2 personnel	Reduced labor cost burden

*Varies based on feed material characteristics.

Technical Specifications

These specifications are representative of a standard model designed as a versatile mini stone crushing plant.

• Capacity/Rating: Up to 120 tph (tonnes per hour), dependent on feed material density and required product size.
• Power Requirements: Option A - Diesel Generator: Tier 4 Final / Stage V compliant, 150 kVA. Option B - Direct Electric Motor Drive: 75 kW main crusher motor.
• Crusher Unit: Jaw Crusher - Feed Opening: 600 x 400 mm; CSS Range: 40 - 100 mm.
• Screen Unit: Two-deck vibrating screen; Top deck aperture: 40-60 mm; Bottom deck aperture: 10-30 mm.
• Conveyors: Main discharge conveyor (folding); Side conveyor for oversize recirculation.
• Material Specifications: Crusher jaw plates manufactured from Mn18Cr2 high-manganese steel; Chassis constructed from high-tensile S355 steel.
• Physical Dimensions (Operating): Length: ~12m; Width: ~2.5m; Height:~4.2m.
• (Transport): Length:~10m; Width:~2.5m; Height:~3.5m.
• Environmental Operating Range: Ambient Temperature: -20°C to +45°C; Dust suppression system included as standard.

Application Scenarios

Demolition & Recycling Contractor | Challenge:

A contractor needed to process concrete and masonry waste from urban demolition sites into certified recycled aggregate. Limited site space, strict noise/dust regulations, and unpredictable material composition were primary constraints.

Solution:

Implementation of an electric-powered mini stone crushing plant with an integrated magnet for metal reclamation. The compact footprint allowed setup within confined areas.

Results:

The plant achieved consistent production of Type 1 sub-base at a rate of 70 tph. On-site processing eliminated haulage fees for waste concrete (~$25/ton), turning a cost center into a revenue stream through aggregate sales.

Rural Road Construction Crew |

Challenge:
A civil engineering team faced high costs and long lead times for importing road base material for a series of small bridge access roads in a remote location.

Solution:

Deployment of a diesel-powered mini stone crushing plant at a local quarry source. The system's mobility allowed it to be moved along the project route as work progressed.

Results:

The crew produced all required sub-base and bedding material on-demand. Project analysis confirmed a net saving of over $80,000 compared to imported materials, even after accounting for fuel and operating costs.

Commercial Considerations

Investing in a mini stone crushing plant involves evaluating total cost of ownership against project requirements.

Equipment Pricing Tiers:

• Base Configuration: Standard model with diesel power unit starts in the range typical for this class of industrial machinery.
• Premium Configuration: Includes added features like hydraulic adjustment on conveyors, radio remote control, upgraded dust suppression systems.

Optional Features:

Common options include an overband magnet for ferrous metal extraction,
a water spray system for dust control,
and different screen meshes tailored to specific product specifications.

Service Packages:

Proactive maintenance plans are available,
including scheduled parts kits,
annual inspections,
and priority technical support
to maximize equipment availability
and manage long-term operating costs.

Financing Options:

Flexible commercial arrangements can be structured,
including equipment leasing programs
and rental-to-own agreements,
to align capital expenditure
with your project cash flow cycles.

Frequently Asked Questions (FAQ)

Q1: What are the primary differences between using this mini stone crushing plant versus renting mobile jaw or cone crushers separately?
The key difference is integration versus componentization. Our solution combines feeding,
crushing,
and screening into one coordinated unit,
designed specifically as an entire circuit.
This eliminates compatibility issues between separate machines,
reduces setup time,
and requires only one power source,
leading to lower operational complexity
and cost compared to managing multiple standalone units.

Q2 Is this equipment suitable for processing reinforced concrete with rebar?
Yes,
when specified with an optional overband magnet.
The jaw crusher is capable of processing concrete with embedded rebar;
the magnet will automatically extract the ferrous metal during operation,
protecting downstream conveyors
and producing cleaner aggregate while generating scrap metal revenue.

Q3 What level of operator skill is required?
The control system is designed around simplicity.
Basic training covers startup/shutdown sequences,
crusher gap adjustment via hydraulic controls,
and daily maintenance checks.
We provide comprehensive operational manuals
and onsite training during commissioning
to ensure your personnel can run the plant effectively within days.

Q4 Can we produce multiple aggregate specifications simultaneously?
Yes;
the integrated screen segregates crushed material into typically two or three predefined sizes discharged onto separate stockpiles via dedicated conveyors;
this allows you to produce both coarse aggregate
and sand fractions in a single pass depending on your screen deck configuration;

Q5 How does financing work typically structured what terms available ?
Financing structures vary based on credit profile business history Common options include straight-line leases term loans Typically terms range from months years down payment requirements vary We recommend discussing specific project details directly obtain tailored quotation payment schedule;

Q6 What kind ongoing maintenance schedule should we expect ?
Maintenance follows predictable intervals Daily greasing bearings visual inspections Weekly checking drive belt tension Monthly inspecting wear parts like jaw liners screen meshes Detailed service schedules checklists provided ensure maintenance performed correctly minimizing risk unplanned downtime;

Q7 Are there limitations types rock can process ?
While versatile these plants optimized medium-hard materials limestone granite basalt recycled concrete Highly abrasive materials like quartzite trap rock will accelerate wear part consumption reducing overall operating economics extremely hard competent igneous rocks may require different crusher technology higher horsepower achieve desired production rates