Setting up a 200 tons per hour (TPH) crushing plant is a big task. It is a “Golden Capacity” for many quarry owners. It is not too big. It is not too small. It fits medium mining projects perfectly. However many people fail. They buy the wrong machines. They lose money on energy. SBM sees this often. We are a manufacturer. We want to help you avoid these mistakes. This article explains how to build a profitable line.
First we define the goal. 200 TPH means processing 200 tons of raw stone every hour. This is the output. The input might be 220 tons. Why? Because some dirt is screened out. The daily output varies. If you work 10 hours you get 2000 tons. If you work 20 hours you get 4000 tons. This scale is flexible. It suits road building. It suits concrete mixing plants. SBM engineers design this for stability.
Every line starts here. You need a primary crusher. The Jaw Crusher is the best choice. SBM uses the PE series usually. Why? It has a big feed opening. It eats rocks up to 600mm or 700mm.
Working Principle: It works like a mouth. There is a fixed jaw plate. There is a moving jaw plate. The motor drives a belt. The belt spins an eccentric shaft. The moving jaw approaches the fixed jaw. The stone gets crushed.
Key Parameter – Nip Angle: This is the angle between jaws. It must be correct. If it is too large the rock pops out. This is dangerous. If too small it wont crush. SBM sets this perfectly.
Why choose it? It handles high compression strength. It is simple to fix. The maintenance is low cost.
This is where people get confused. Do you use an Impact Crusher? Do you use a Cone Crusher? The answer depends on your stone. You must know your stone hardness. We use the Mohs scale.
Option A: Impact Crusher (Soft Rock)
Use this for Limestone. Use it for Gypsum. The SBM CI5X series is good. It uses impact energy. A rotor spins fast. Blow bars hit the stone. The stone hits impact plates.
Why? It makes a cube shape. The product looks good. It sells for a high price. But do not use for granite. The wear parts will die in 2 days. That is too expensive.
Option B: Cone Crusher (Hard Rock)
Use this for Granite. Use for Basalt. Use for River Stone. The SBM HST series is famous. It crushes by squeezing.
Why? The mantle and concave are made of manganese steel. They last long. The operating cost is lower for hard rock. The initial price is higher. But you save money later.
You must understand these terms. They control your money.
CSS (Closed Side Setting): This is the smallest gap between crusher jaws. It happens during the crushing cycle. It determines your final product size. If you want 20mm stone set CSS near 20mm.
OSS (Open Side Setting): This is the largest gap. It affects the throughput.
Why care? If CSS is too tight the power spikes. The amp meter goes red. You burn the motor. If CSS is too loose you get oversized rocks. You must balance this. SBM manuals show the exact chart.
This is a common pain point. Customers ask this often. “My liner breaks in a week.” Why? usually it is the feed.
The Solution: check the fines. Are you feeding dust into the crusher? You should not. Use a vibrating feeder with grizzly bars. The bars let small dirt fall through. This is “Scalping”.
Why do this? It reduces wear. Metal on metal wear is bad. Rock on rock is better. Also check the chamber level. A cone crusher must be full. We call this “Choke Feeding”. If it is half empty the rocks slap the sides. The liner cracks. Keep it full.
Let us look at a real job. The client is in Manila. They have River Stone. This is very hard rock. Silica content is high.
The Problem: They used an impact crusher before. The blow bars wore out every 20 hours. They lost profit. They were angry.
The SBM Solution: We changed the design. We installed a PE750x1060 Jaw Crusher. Then we added an HPT300 Cone Crusher.
The Result: The wear liners now last 2 months. The output is stable at 210 TPH. The customer said “SBM saved our business.”
Why it worked: We matched the machine to the stone. Hard stone needs compression not impact.
Another client has a quarry in Java. The stone is limestone. It is soft.
The Setup: We used a Feeder. Then a PE Jaw Crusher. Then a PFW Impact Crusher. Finally a Vibrating Screen.
Technical Data: The impact crusher runs at 600 RPM. The gap is adjustable hydraulically.
The Feedback: The stone shape is perfect. It is cubical. Concrete plants love it. The cement sticks better. The client sells it for a premium price.
Why it worked: Impact crushers shape the stone. Limestone does not kill the blow bars fast.
Energy is a big cost. You do not want a huge motor on a small crusher. It wastes electricity.
The Rule: Look at the crushing ratio. If you crush from 500mm to 50mm the ratio is 10. You need high power.
Data Evidence: Academic journals say energy efficiency is key. Grinding uses 50% of mine power. Crushing uses less. But efficient motors help. SBM uses Siemens or WEG motors. They are efficient.
Why? A cheap motor overheats. It stops the line. You lose 200 tons every hour it stops. Good motors run cool.
Here is a typical setup list. This helps you plan.
| Stage | Equipment Model | Power (kW) | Function |
|---|---|---|---|
| Feeding | ZSW490x110 | 15 | Feed raw stone evenly |
| Primary | PE750x1060 | 110 | Crush big rocks to medium |
| Secondary | HPT300 / CI5X1520 | 250 / 280 | Crush to final size |
| Screening | 4YZS2160 | 30 | Separate sizes (10/20/30mm) |
| Conveying | B800 / B1000 | Var | Transport material |
Many old quarries use manual buttons. Is this bad? Yes.
The Upgrade: SBM offers PLC control systems. You sit in a room. You look at screens.
Why use it? You see the amps. You see the heat. If the oil pressure drops the machine stops itself.
The Benefit: It prevents huge failures. It removes human error. A tired worker might miss a warning light. The computer never misses. It saves repair costs.
Buying is step one. Installing is step two.
Foundation: Concrete must be cured. It takes 28 days usually. Do not rush. The vibration is strong. Weak concrete will crack.
V-Belts: Check the tension. Loose belts slip. They burn. Tight belts hurt bearings.
Lubrication: This is life. Grease the bearings every shift. Change oil filters.
Why? Dirt kills bearings. Dust is the enemy. SBM seals are tight. But you must be clean.
Governments are strict now. You cannot make a dust cloud.
Solution 1: Water Spray. Put nozzles at the discharge points. It wets the stone. Dust stays down.
Solution 2: Bag Filters. SBM makes dust collectors. They suck the air. They trap the dust.
Why bother? If you pollute they close you down. It is simple. Also it protects workers lungs.
You spend money to make money.
Cost Factors: Machine cost. Land cost. Power cost. Labor cost. Wear parts cost.
Profit Factors: Sale price of stone. Volume sold.
Calculation: A 200 TPH line produces 2000 tons a day. If profit is $2 per ton that is $4000 a day. The machine pays for itself in 6 months to 1 year.
Why SBM? Our machines run 95% of the time. Cheap machines run 70% of the time. That downtime kills your ROI.
Setting up a 200 TPH line requires smarts. You need the right Jaw. You need the right Cone or Impact. You need to watch the CSS. You need to grease the bearings.
SBM is a manufacturer. We are not just a shop. We have factories. We have engineers. We provide the full design. We send guys to install. We train your workers.
Do you have hard rock? Do you have soft rock? Tell us. We build the solution for you. We help you make money. Contact SBM today for a price list. Let us start digging.
Whatsapp：+8617329420102
Email: [email protected]
Address: No. 1688, Gaoke East Road, Pudong new district, Shanghai, China.
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