A client in the paper industry in Tuban, Indonesia, faced a critical challenge: his existing crushers couldn’t produce the large-sized limestone needed to meet booming demand. With production delays and missed sales opportunities, they turned to AIMIX Group for a high-efficiency crushing solution. Then, a tailor-made 200 tph limestone crushing plant was designed by us to solve his troubles and position him as a regional industry leader.
What Challenges and Requirements do Customers Face?
- Production Shortfalls: Existing crushers couldn’t process large 500mm+ limestones, he needed to process 200 tons/hour to meet internal paper production and external sales.
- Size Matters: Required 5-40mm uniformly sized limestone aggregates for better paper production efficiency.
- Speed to Market: Needed operational readiness by Q4 2024 to capitalize on market opportunities.
- Minimal Downtime: Previous setups suffered from frequent breakdowns, hurting productivity.
AIMIX’s Customized Solution: Precision Engineering for Maximum Output
To address the client’s pressing challenges, AIMIX engineered a fully integrated stationary limestone crushing plant that combined advanced technology, robust construction, and intelligent automation for high-volume production.
Crush Faster & Smarter
- Dual-Stage Jaw Crushers: Equipped with two stages crushing, the main crushing equipment is APJ-6090E & APJ-1012E jaw crushers. They are engineered to handle large 500mm limestone blocks with high reduction ratios, ensuring optimal fragmentation in fewer passes.
- Smart Load Adjustment: Hydraulic toggle systems and reinforced bearings minimized energy waste while preventing overloads.
Flawless Material Flow
- High-Capacity Feeders: Auto-regulated feeding through GZD-250X120 & APG-600X130 models eliminated jams and uneven throughput, critical for maintaining 200t/h output.
- Low-Friction Conveyor Belts: Heavy-duty rubber belts with impact-resistant idlers reduce spillage and extend component life.
Precision Grading for Premium Aggregates
- APS-2160Y4 Vibrating Screen: Multi-layer screening decks produced 4 calibrated sizes: 5-10mm, 10-15mm, 15-20mm and 20-35mm, meeting exact paper industry specs.
- Dust Suppression Integration: Water sprays kept airborne particles in check, improving workplace safety.
Results: Crushing Goals, Delivering Profits
After installing and running, the results matched what our clients wanted perfectly, turning his operations into a high-efficiency, profit-generating powerhouse. The AIMIX limestone crushing plant was making a real difference for his business.
| Client Need | Result |
|---|---|
| Process Large Limestone | 500mm rocks crushed effortlessly; 200T/H output achieved. |
| 5-40mm Aggregate Production | 98% of output met exact size specs, optimizing paper production efficiency. |
| Operational by December 2024 | Plant commissioned 3 weeks ahead of schedule. |
| Downtime Elimination | Predictive maintenance cut downtime by 90% vs. legacy systems. |
| Added Value | Achieve 30% higher sales of premium aggregates. |
The client’s feedback: “We went from struggling to keep up to having more than enough high-quality material. Now we’re not only supplying our paper industry, but selling to construction companies, thanks to this partnership, which has built our competitive advantages.”
Conclusion
The 200TPH limestone crushing plant not only solved our client’s immediate production challenges but also unlocked new revenue streams and positioned their business for long-term growth. At AIMIX, we specialize in designing customized crushing solutions that drive real business results. Whether you need to boost capacity, improve product quality, or reduce operational costs, our team will work closely with you to develop the perfect system for your unique requirements. Contact us to discuss how we can help you achieve crushing success. Let’s build your competitive advantage together!
