Crushing & Screening Plants About Information
The foundation of every successful quarry operation lies in the quality and efficiency of its crushing and screening equipment. Whether processing granite, basalt, limestone, or other aggregate materials, selecting the right rock crusher configuration determines production capacity, end product quality, and operational profitability. At Constmach, we design and manufacture complete stone crushing and screening plants that transform raw quarry material into precisely graded aggregates for construction projects worldwide. Our systems integrate multiple crushing stages with advanced screening technology to deliver consistent particle size distribution and maximum yield from every ton of material processed.
Modern aggregate production demands more than basic crushing equipment. Today's quarry operations require sophisticated plants that optimize energy consumption, minimize maintenance downtime, and adapt to varying material characteristics. Constmach plants combine robust mechanical design with intelligent automation systems that monitor and adjust crushing parameters in real-time. From primary jaw crushers handling massive boulders to tertiary impact crushers producing sand-sized particles, each component works in harmony to maximize throughput while maintaining strict quality standards. Our complete plant solutions include everything from wobbler feeders that remove fines before crushing to belt conveyors that efficiently transport material between process stages.
Stationary crushing plants form the backbone of high-capacity aggregate production operations. These permanent installations deliver exceptional stability and processing power for quarries producing hundreds or thousands of tons daily. Constmach stationary plants feature heavy-duty steel frameworks designed to withstand decades of continuous operation while supporting the substantial forces generated during rock crushing. The modular design allows for customized configurations that match specific production requirements, material characteristics, and site conditions. Each plant integrates seamlessly with existing quarry infrastructure, and the fixed installation eliminates setup time associated with mobile equipment.
Jaw crushers serve as the workhorse of primary crushing operations, accepting large quarry run material directly from blasting operations. Our jaw crushers utilize a simple yet highly effective crushing mechanism where material is compressed between a fixed jaw plate and a moving jaw plate in a V-shaped chamber. This compression crushing action excels at processing extremely hard materials like granite and basalt stone, reducing boulders up to 1200mm to manageable sizes for secondary processing. The robust construction features cast steel frames, manganese steel wear parts, and heavy-duty flywheels that maintain crushing momentum even under peak loads.
Primary impact crushers offer an alternative to jaw crushers, particularly effective with less abrasive materials like limestone. These machines use high-speed rotor impact rather than compression, throwing material against stationary anvils and using kinetic energy to shatter rock along natural fracture lines. The result is a more cubical product with reduced needle and flake particles compared to jaw crushing. Constmach primary impact crushers feature adjustable rotor speeds and hydraulically adjustable curtains that allow operators to fine-tune the crushing process for different material types and desired product specifications.
After primary crushing, material moves to secondary impact crushers for further size reduction. These machines process material in the 200-300mm range, producing aggregates suitable for base courses and larger concrete applications. The horizontal shaft design creates a controlled crushing environment where material cascades through multiple impact curtains, each reducing particle size progressively. Hydraulic opening mechanisms provide quick access to the crushing chamber for maintenance and wear part replacement, minimizing downtime in demanding production schedules.
Tertiary impact crushers refine aggregates to their final product specifications, typically producing materials from 0-31.5mm. These precision machines operate at higher speeds than secondary crushers, generating the impact energy necessary to shape particles and create the cubical aggregates required for high-quality concrete and asphalt production. Adjustable crushing settings allow operators to shift production between different product grades without equipment changes, providing operational flexibility that maximizes quarry profitability.
Vertical shaft impact crushers (VSI) represent the most advanced technology for producing manufactured sand and premium cubical aggregates. Material is accelerated through a high-speed rotor and ejected against either a rock-lined chamber (rock-on-rock crushing) or against steel anvils (rock-on-steel). This process not only reduces particle size but actively shapes aggregates, breaking elongated particles and producing the consistently cubical products demanded by modern construction specifications. Constmach VSI crushers deliver superior particle shape compared to conventional crushing methods, essential for high-performance concrete applications.
Cone crushers excel in secondary and tertiary applications requiring high reduction ratios and consistent product sizing. The crushing action occurs between a gyrating mantle and a concave bowl liner, applying compression forces that efficiently break rock while consuming less energy than impact crushing. These machines are particularly valuable for processing hard, abrasive materials like granite and basalt where wear resistance is critical. Multiple cavity designs allow a single cone crusher to produce different product sizes by simply changing the crushing chamber configuration.
Wobbler feeders install at the plant infeed to scalp out undersized material before it enters the primary crusher. The unique wobbling motion of these feeders effectively separates fines and small material that has already achieved target size, preventing unnecessary crushing and reducing wear on downstream equipment. This pre-screening dramatically improves plant efficiency by allowing crushers to focus on material that actually requires size reduction.
Vibrating feeders regulate material flow to crushers, ensuring consistent feed rates that optimize crushing performance. Constmach feeders feature heavy-duty vibrating mechanisms that handle large rocks without bridging or blockages. Variable frequency drives allow precise adjustment of feed rates to match crusher capacity and prevent overloading. The grizzly bar design available on some models provides additional scalping capability, further improving system efficiency.
Vibrating screens separate crushed material into precisely sized fractions, ensuring each product meets specification requirements. Multi-deck screen designs create multiple product sizes from a single material stream, with each deck using different mesh openings to separate specific size ranges. High-frequency vibration combined with properly selected screen media guarantees accurate separation even at high throughput rates. Constmach screens incorporate dust suppression systems and modular screen panels for quick media changes between product runs.
Belt conveyors form the circulatory system of crushing plants, moving material efficiently between processing stages. Constmach designs complete conveyor systems with proper belt selection, drive configurations, and support structures that ensure reliable operation under demanding conditions. Each conveyor features adjustable speed controls, automated tracking systems, and strategically positioned transfer points that minimize material spillage and maintenance requirements. Proper conveyor design prevents bottlenecks that would otherwise limit plant capacity.
Hydraulic hammer breakers address the inevitable problem of oversized material or bridging in feed hoppers and crusher inlets. Rather than shutting down the plant to manually clear blockages, operators use these hydraulic-powered breakers to fragment problem material quickly and safely. The fixed mounting positions these tools at critical points throughout the plant where oversized material typically causes problems, maintaining production continuity and protecting equipment from damage.
Selecting a crushing plant represents a substantial capital investment that will define your quarry's capabilities for decades. Constmach delivers more than equipment – we provide complete crushing solutions backed by engineering expertise and global support infrastructure. Our plants are engineered specifically for the aggregate industry, incorporating features learned from thousands of installations worldwide. Every component is selected for durability and ease of maintenance, recognizing that equipment uptime directly impacts profitability.
When you partner with Constmach, you gain access to our technical team who works alongside you from initial concept through commissioning and beyond. We analyze your material characteristics, production requirements, and site conditions to configure plants that optimize your specific operation. Our manufacturing facilities utilize advanced fabrication techniques and stringent quality control to ensure every plant meets our exacting standards. From the largest stationary plant processing 1000 tons per hour to compact configurations for specialized applications, we engineer solutions that maximize your return on investment through superior performance, reliability, and product quality. Contact us today to discuss how Constmach crushing technology can transform your aggregate production operation.
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