Stationary Crushing and Screening Plants

When it comes to designing a crushing and screening plant, one size definitely doesn't fit all. CONSTMACH understands this reality and builds each plant around what clients actually need, not what looks good on paper. Production capacities span from 50 to 1,000 tons per hour, but that number alone doesn't tell the whole story. What matters more is how the plant performs with your specific material under your actual site conditions.

The engineering team starts by examining several critical factors that will determine the plant's configuration. First, there's the production capacity requirement, which goes beyond just hitting a tonnage number. It's about maintaining that output consistently throughout operating hours. Then comes the material itself: limestone behaves very differently from basalt or granite. A soft, non-abrasive material allows for different crusher selections compared to hard, abrasive rock that demands wear-resistant components. The maximum feeding size plays an equally important role since it directly influences primary crusher selection and feeder specifications. Finally, the required final product fractions define the screening setup and whether secondary or tertiary crushing stages are necessary.

CONSTMACH's approach centers on flexibility in crusher selection. Jaw crushers typically handle primary crushing duties for larger feed sizes, while impact crushers work efficiently with softer to medium-hard materials. Cone crushers excel in secondary and tertiary stages, particularly with harder rock types. The design team can integrate different crusher types within a single plant layout, matching each stage to the material characteristics at that point in the process. This isn't about using every crusher type available but selecting the right combination that delivers the required product quality at the lowest operational cost.

The 3D layout process brings together feeders, crushers, screens, hoppers, washers, and conveyors into a cohesive system. Each component's size and specification gets calculated based on material flow rates, surge capacity requirements, and space constraints. Conveyor angles, lengths, and belt speeds are determined to ensure smooth material transfer between stages without bottlenecks. Screen decks are configured with appropriate mesh sizes and inclination angles to achieve the desired product separation. This detailed planning phase prevents the costly mistakes that emerge when components don't work together as an integrated system.

Avoiding mis-investment stands as a core principle in CONSTMACH's engineering philosophy. Oversized equipment wastes capital and increases energy consumption. Undersized components create production bottlenecks and excessive wear. The goal is finding that optimal balance where the plant delivers required output without unnecessary overhead. This means sometimes recommending a smaller plant with the right configuration over a larger one that looks impressive but doesn't match actual needs.

The automation system incorporates SIEMENS and SCHNEIDER components with PLC control, providing operators with real-time monitoring and adjustment capabilities. This isn't just about having recognizable brand names. These systems offer proven reliability in dusty, high-vibration environments where crushing plants operate. The control interface allows operators to adjust feed rates, monitor crusher parameters, and track production output while maintaining equipment within safe operating limits.

Technical specifications vary significantly based on three primary variables: the target production capacity, the number and sizes of final product fractions needed, and the material type being processed. A plant producing three different aggregate sizes from limestone will have a completely different configuration than one processing granite into two sizes, even if both target 300 tons per hour. This is why CONSTMACH's engineering team prepares customized proposals rather than offering standard packages. Contact their team with your specific requirements, and they'll develop a layout optimized for your application, helping you avoid both underspending that leads to inadequate performance and overspending on unnecessary capacity.