50–80 t/h Stone Crushing Plant
Product Overview
This 50–80 tonnes-per-hour stone crushing plant is a compact, ready-to-run aggregate production line for small-to-medium quarries, concrete batching plants, road-building contractors and construction-waste recycling yards. It is built around four proven machines: a ZSW850x3000 vibrating feeder that meters run-of-mine rock, a PE500x750 jaw crusher for primary compression crushing, a PF1010 horizontal-shaft impact crusher for cubical shaping, and a 2YK1860 two-deck vibrating screen that splits the final product into graded fractions and recycles oversize back to the impactor.
The plant accepts feed up to roughly 500 mm and discharges finished aggregates of 0–5, 5–10, 10–20 and 20–31.5 mm. It is suitable for limestone, granite, basalt, river pebble, dolomite, blast furnace slag and recycled concrete. Total installed power is around 75 kW, keeping both capital cost and electricity bill within reach of smaller operators.
Working Principle and Process Flow
Run-of-mine rock is tipped into the dump hopper by an excavator. The ZSW850x3000 feeder below uses two synchronized vibration motors to throw material forward in an even stream. The slotted trough bottom acts as a grizzly: fines and soil drop through and bypass the jaw, while lumps travel onto the belt to the PE500x750.
Inside the jaw crusher, an eccentric shaft drives the movable jaw against the fixed jaw. Rock entering the 500 × 750 mm opening is squeezed until it falls through the adjustable 50–100 mm discharge gap. This primary product is then conveyed to the PF1010 impact crusher.
In the impactor, a rotor spinning at 600–750 rpm flings the rock against two heavy aprons and against itself. High-speed impact fractures the stone along its natural cleavage planes, producing a cubical, low-flakiness aggregate. Adjustable apron gaps tune the product from 0–40 mm down to a finer 0–20 mm.
The shaped material is lifted to the 2YK1860 screen with two 1800 × 6000 mm decks. The top deck scalps oversize stone back to the impactor; the middle and bottom decks separate coarse and fine fractions, yielding three or four stockpiles.
Equipment Description
3.1 ZSW850x3000 Vibrating Feeder
ZSW850x3000 Vibrating Feeder
Trough-type feeder with a 3000 × 850 mm steel trough. Two 2 × 1.5 kW vibration motors create a linear throwing motion that advances material at a controlled rate. A discharge-end gate sets the feed rate so the jaw crusher is never overloaded. The slotted grizzly deck removes fines before primary crushing, extending jaw liner life. Nominal throughput is 80–150 t/h, above the plant's 50–80 t/h target.
3.2 PE500x750 Jaw Crusher (Primary)
PE500x750 Jaw Crusher (Primary)
Single-toggle jaw crusher with a 55 kW motor, cast-steel flywheel and manganese-steel jaw plates. Accepts up to 425 mm feed and discharges through a 50–100 mm adjustable CSS. Crushing ratio is 4:1 to 6:1, and the machine handles abrasive basalt and granite with predictable wear. Rear shim plates allow quick CSS changes. Weight about 12 tonnes.
3.3 PF1010 Impact Crusher (Secondary / Shaping)
PF1010 Impact Crusher (Secondary / Shaping)
Uses a 1000 mm diameter, 1050 mm wide rotor with high-chrome blow bars and two adjustable impact aprons. Feed up to 350 mm is reduced to a cubical 0–40 mm product with very low flake content, preferred for concrete and asphalt aggregate. Apron gaps, rotor speed and blow-bar material are selected against the rock's abrasiveness.
3.4 2YK1860 Vibrating Screen (Final Sizing)
2YK1860 Vibrating Screen (Final Sizing)
Inclined two-deck circular-motion screen with a 1800 × 6000 mm panel per deck. Two 5.5 kW vibrator motors drive the deck at about 850 rpm. Panels are interchangeable: common openings are 31.5 mm, 10 mm and 5 mm, yielding four discharge points. Handles 60–200 t/h of wet or dry feed; rubber or polyurethane decks available for abrasive material.
| Parameter | ZSW850×3000 Feeder | PE500×750 Jaw | PF1010 Impactor | 2YK1860 Screen |
|---|---|---|---|---|
| Role | Feeding + pre-screening | Primary crushing | Secondary shaping | Final sizing |
| Feed size | ≤500 mm | ≤425 mm | ≤350 mm | ≤200 mm |
| Output size | Adjustable gate | 50–100 mm CSS | 0–40 mm | 0–5 / 5–10 / 10–20 / 20–31.5 mm |
| Capacity (t/h) | 80–150 | 40–110 | 50–80 | 60–200 |
| Power (kW) | 2 × 1.5 | 55 | ~45 | 2 × 5.5 |
| Main dimensions | 850 × 3000 mm trough | 500 × 750 mm jaw opening | Ø1000 × 1050 mm rotor | 1800 × 6000 mm, 2 decks |
| Approx. weight | ~3.5 t | ~12 t | ~12 t | ~7.8 t |
Typical Product Gradation at 60 t/h
When processing medium-hard limestone (compressive strength ≤ 160 MPa) with a 65 mm CSS on the jaw and standard apron settings, the plant typically splits output as follows: 0–5 mm fines about 20% (plaster or concrete sand); 5–10 mm small aggregate about 25% (asphalt and drainage); 10–20 mm medium aggregate about 30% (ready-mix concrete); 20–31.5 mm coarse aggregate about 25% (road base and structural concrete). For harder granite or basalt, the fines share rises slightly and throughput holds at 50–65 t/h.
Key Advantages
The plant is a matched set: the feeder's capacity is sized to the jaw, the jaw's discharge matches the impactor's intake, and the screen area is generous enough that even wet feed does not blind the meshes. All four machines share a common electric control cabinet with interlocks that stop the feeder upstream if any downstream machine trips.
Maintenance is designed around the parts that consume money: jaw plates, blow bars, impact aprons and mesh panels. Each can be replaced from outside the machine without removing the rotor, and spares are standardized across the manufacturer's range. At 60 t/h the line draws 60–70 kW, about 1.0–1.2 kWh per tonne. Because the impactor produces cubical product directly, no separate sand-making step is needed to meet concrete-spec flake limits.
Applications
Typical users include quarries producing graded aggregate for local concrete plants; highway and railway contractors producing road base on site; recycling yards processing demolished concrete into reusable 0–31.5 mm aggregate; small mines reducing ore ahead of ball mills; and cement plants processing limestone additives. The plant can be skid-mounted on a fixed steel frame or mounted on a wheeled or tracked chassis for contractors who move between job sites.
Installation and After-Sales
Standard units ship within 25–35 days after deposit, packed for sea freight. A team of two technicians normally completes erection and commissioning in 15–25 days, and trains the customer's operators on start-up, CSS adjustment and wear-part replacement. The manufacturer supplies a spare-parts list for the first 2,000 operating hours and guarantees the main frames for one year or 4,000 hours.
Frequently Asked Questions
Q1. What is the real capacity?
A. Designed at 50–80 t/h for medium-hard rock. Soft limestone runs near 80 t/h; abrasive granite or a tight CSS pulls it toward 50 t/h.
Q2. Can it process granite or basalt?
A. Yes. For highly abrasive rock we recommend high-chrome blow bars on the PF1010 and shorter inspection intervals.
Q3. How is the finished gradation changed?
A. By swapping screen mesh panels on the 2YK1860 and adjusting the impactor apron gaps. The jaw CSS only changes if the upstream feed size changes.
Q4. What is included in the standard package?
A. The four core machines, dump hopper, belt conveyors, electric control cabinet and steel frames. Dust suppression, bag filters and chassis mount are optional.
Q5. How long is delivery?
A. 25–35 days after deposit; installation and commissioning 15–25 days on site.
Baichy Heavy Industry
Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 、certified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.
Baichy Heavy Industry – Your Trusted Partner
To ensure optimal performance of your equipment, Baichy Heavy Industry offers:
- Professional on-site installation guidance
- Comprehensive operator training
- 24/7 technical support & maintenance services
Our complete after-sales service system guarantees long-term, stable operation of your machinery with minimal downtime.
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