According to the description from our Mexican client, they are setting up a quarry and need a complete crushing and screening production line. Their core requirements include:
1. Jaw Crusher Front-End Feeding System
• A feeder is needed that matches the size of the 80×50 cm jaw crusher.
• The feeder should be able to feed the jaw crusher evenly and continuously to ensure crushing efficiency.
2. Jaw Crusher Back-End Conveying System
• A vibrating chute (vibrating feeder) is needed after the jaw crusher.
• Used to transport the coarsely crushed material to the next stage of crushing equipment.
3. Secondary/Tertiary Crushing System
• A cone crusher with an inlet diameter of 120 cm is needed.
• Used for secondary crushing of the coarse material produced by the jaw crusher.
4. Screening and Grading System
• A vibrating screen with dimensions of approximately 400×150 cm is needed.
• Used to screen the crushed material into different sizes of finished products.
Feeder + Jaw Crusher - Customer Site
Feeding System Configuration
Vibrating Feeder (ZSW490×110)
For the feeding requirements of the 80×50 cm jaw crusher, we recommend the ZSW490×110 vibrating feeder. This equipment uses a double eccentric shaft exciter structure, with a feeding capacity of 250-380 t/h, a feed size of ≤300 mm, and a motor power of 15 KW. Its advantages include:
• Variable frequency speed control allows for precise adjustment of the feeding volume, preventing jaw crusher jamming.
• Adjustable bar spacing provides pre-screening functionality, allowing fine materials to directly enter the finished product.
• Wear-resistant liners are made of high-manganese steel, extending the service life by more than 30%.
Vibrating Chute (Bar Vibrating Feeder GBZ1200×L)
The vibrating chute after the jaw crusher uses a GBZ1200×L bar vibrating feeder. The length is determined according to the site layout (usually 3-10 meters), and the motor power is 7.5-18.5 KW. The equipment features:
• Heavy-duty plate structure, capable of withstanding the impact of large materials
• Pre-screening function to remove fine materials directly into the finished product, reducing the load on the jaw crusher
• Hydraulically adjustable discharge opening for easy operation
Limestone crushing production line at a customer's site.
Crushing System Configuration
Jaw Crusher (PE750×1060)
As a primary crushing equipment, the PE750×1060 jaw crusher has a feed opening of 630mm, a processing capacity of 72-130 t/h, and a motor power of 90KW. Equipment features:
• Deep cavity crushing design, large crushing ratio, and uniform product particle size
• Hydraulically adjustable discharge opening with an adjustment range of 95-165mm
• Movable jaw made of high-manganese steel for strong wear resistance
Cone Crusher (PYB1200)
A PYB1200 cone crusher is configured to meet the requirement of a 120 cm feed opening diameter. This equipment has a feed particle size of ≤145mm, a processing capacity of 110-168 t/h, and a motor power of 132KW. Technical advantages:
• Single-cylinder hydraulic system for convenient and accurate discharge opening adjustment
• Large crushing ratio, low energy consumption, and excellent finished product particle shape
• Suitable for secondary crushing operations, with adjustable output particle size
Crushing and screening equipment at a customer's site.
Screening System Configuration
Vibrating Screen (2YK2460)
A 2YK2460 vibrating screen with a size of 400×150 cm is used, with a screen surface size of 2.4×6.0 meters and 2 layers of screen mesh. Equipment Features:
• Processing capacity: 200-900 t/h, screening efficiency ≥85%
• Uses rubber spring vibration damping, noise level below 75 decibels
• Screen mesh made of polyurethane material, with a lifespan 3 times longer than metal screens
Layout diagram of a 100-150 tph limestone crushing production line
Complete Production Line Process Flow
Process Flow:
Stone → Vibrating Feeder → Jaw Crusher (Coarse Crushing) → Vibrating Trough → Cone Crusher (Medium Crushing) → Vibrating Screen → Finished Product
Technical Parameters:
| Processing Capacity | 100-150 t/h |
| Feed Size | ≤630mm |
| Finished Product Specifications | 0-5mm, 5-10mm, 10-20mm, 20-31.5mm |
| Total Installed Power | Approximately 300KW |
Equipment Advantages and Features
Technical Advantages
High Efficiency and Energy Saving
• Optimized cavity design, crushing efficiency increased by more than 20%
• Intelligent hydraulic system control, energy consumption reduced by 15%-30%
• Closed-loop circulation system, material can be crushed to below 20 mesh in three cycles
Stable and Reliable
• Core components use wear-resistant materials such as high-manganese steel and high-chromium alloy
• Bearings use imported brands, extending service life by 50%
• Hydraulic protection device, automatic overload protection to prevent equipment damage
Intelligent Control
• PLC control system, achieving one-button start and stop
• Remote monitoring function, real-time monitoring of equipment operating status
• Fault diagnosis system, early warning of potential faults
Environmental Performance
• Fully enclosed design, dust emission concentration ≤10mg/m³
• Noise control ≤75 decibels, meeting environmental requirements
• Wastewater recycling, achieving zero discharge
Successful Cases
Case 1: Philippines 1000 tons/hour Quarry Project
• Configuration: 2 PE1500×1200 jaw crushers + 2 PF1820 impact crushers + 4 2YK3072 vibrating screens
• Finished Product: High-quality crushed stone aggregate (5-10mm, 10-20mm, 16-31.5mm)
• Operating Performance: The equipment ran continuously for 180 days without downtime, and the finished product pass rate was ≥98%.
Case Study 2: Mexico 300 tons/hour Granite Production Line
• Configuration: CH250 single-cylinder cone crusher + 2 HP200 multi-cylinder hydraulic cone crushers + PF1320 impact crusher
• Finished Product Specifications: 1-5mm, 5-10mm, 10-20mm, 20-30mm, 30-40mm
• Operating Performance: Stable output of 350 tons per hour, equipment failure rate <3%
Case Study 3: Zhejiang Jiaotou Haixin Mining Project
• Configuration: CJ1500 jaw crusher + 4 SC360S single-cylinder cone crushers
• Processing Capacity: 1500 t/h
• Operating Performance: Actual capacity reached 1700 t/h, exceeding expectations, with excellent finished product particle shape.
Crushing Production Line Investment Suggestions
Investment Budget
The total investment for a quarry production line with a capacity of 100-150 tons per hour is approximately 1.5-3 million RMB (excluding civil engineering), including:
• Equipment purchase cost: 1-2 million RMB
• Installation and commissioning costs: 0.1-0.2 million RMB
• Supporting equipment (conveyors, dust removal, etc.): 0.2-0.4 million RMB
• Spare parts and tools: 0.1-0.2 million RMB
Return on Investment
• Construction period: 2-3 months
• Investment payback period: 1-2 years (calculated based on sand and gravel price of 30-50 RMB/ton)
• Annual profit: 1.5-3 million RMB (based on annual output of 300,000-500,000 tons)
Perfect after-sales service
Baichy Heavy Industry provides professional on-site guidance for installation, training of workers, and other services to ensure that customers can use the equipment smoothly.
The company has a complete after-sales service system, which can provide customers with timely technical support and equipment maintenance services to ensure the long-term stable operation of the equipment.
To prevent the rights and interests of customers from being infringed, Baichy Heavy Industry reminds customers: please contact our customer service staff through the official website of Baichy Heavy Industry , or add WhatsApp: 15093222637 ; or send an email to: [email protected] , we will get in touch with you as soon as possible and provide you with the most professional service in the industry.
Baichy Heavy Industry
Baichy Machinery is a factory supplier of mining machinery, mainly focusing on stone crushers, powder grinding mills, and mineral beneficiation plants. We can offer you a free design and completed solutions according to your project.
Baichy Heavy Industry has grown into a high-tech mining equipment comprehensive enterprise, integrating R&D, manufacturing, sales, and after-sales service, Passing ISO9001:2015 quality management system certifications. The main products are mobile jaw crushing plants, construction waste crushing plants, PE jaw crushers, VSI sand-making machines, Symons cone crushers, single-cylinder hydraulic cone crushers, PCX high-fine crushers, grinding mills, ball mills, and full sets of beneficiation equipment with an excellent level.
