/ Equipment service
Crushing and screening plants
We restore crusher and screen throughput and upgrade the line for new tasks.
- 016 unit types
- 02Site visits: KZ & CIS
- 0312-mo warranty
/ Equipment
Types of units we work with
Crushing equipment
Jaw, cone, roll, hammer and other crushers within the company's actual service competence.
Vibrating screens
Drives, vibration exciters, screen boxes, screening media, spring elements and support structures.
Feeders
Vibrating, apron and other metered material feed systems.
Conveyor equipment
Drive and take-up stations, pulleys, idlers, belt, loading and discharge points.
Feed chutes
Diagnostics of housing and liner wear and material flow geometry.
Drive equipment
Electric motors, gearboxes, couplings, shafts, bearing units and gear drives.
/ Technical audit
We look at the entire process line, not just one unit
The technical audit covers raw material input data, the crushing and screening flowsheet and the actual condition of the machines.
Input data
- Feed Rate
- t/h
- Feed Size
- 0–XXX mm
- Max Lump Size
- XXX mm
- Bulk Density
- t/m³
- Moisture
- %
- Required Product
- mm
- Bond WI
- if known
- Abrasion
- if known
ROM → PRODUCT
ROM
0–500 mm
Feeder
350 t/h
Primary Crusher
P80 = XXX mm
Screen
XX mm
Secondary Crusher
Product
Stockpile
What we check
Crushing chamber
- wear of working parts
- liner condition
- chamber profile
- gap setting
- wear uniformity
Shaft and bearings
- vibration
- temperature
- play
- fits
- lubricant condition
Drive
- motor
- belt/coupling drive
- gearbox, if fitted
- alignment
- load
Housing
- cracks
- deformations
- welds
- fastenings
Lubrication system
- pressure
- flow rate
- temperature
- contamination
- pump condition
/ Audit result
After the inspection the customer receives
- 01
List of identified defects
- 02
Technical condition assessment
- 03
List of units requiring repair or replacement
- 04
Upgrade recommendations
- 05
Preliminary spare parts list
- 06
Proposed scope of work
- 07
Technical proposal
/ Repair
Partial repair and overhaul
Partial repair
Possible work when the crushing and screening equipment retains its main service life.
- frame repair
- seat restoration
- bearing replacement
- shaft repair
- eccentric assembly repair
- liner replacement
- drive repair
- lubrication system repair
- parts manufacturing
- restoration of feed/discharge points
Overhaul
An overhaul involves in-depth fault detection with restoration or replacement of worn main units.
- 01
Disassembly and fault detection
Determining the actual condition of parts and units.
- 02
Restoration
Machining, repair or manufacture of parts.
- 03
Replacement
Installation of new components where restoration is technically or economically unjustified.
- 04
Assembly and adjustment
Restoring geometry, adjusting mechanisms and drives.
- 05
Testing
Testing of equipment systems.
- 06
Commissioning
Installation supervision and commissioning, depending on the scope of work.
Vibrating screen service
Allowable vibration and other parameter values depend on the equipment and the assessment method — universal limits are not given on the website.
We diagnose
- screen box
- beams
- welds
- vibration exciters
- bearings
- drive
- springs
- screening media
- panel fastening
- feed distribution
Possible work
- Vibration exciter replacement
- Screen box and beam repair
- Spring replacement
- Screening media replacement
- Restoring panel fastening
- Drive balancing
Key monitoring parameters: capacity, feed size, aperture, frequency, amplitude, inclination, deck area, deck quantity.
/ Upgrade
Improving the efficiency of existing equipment
Upgrading the crushing and screening line is often more effective than replacing a single machine.
Higher throughput
Analysis of process line bottlenecks.
Change of product size
Adjusting the crushing and classification circuit.
Reduced circulating load
Optimising the operation of screens and crushing equipment.
Reduced downtime
Addressing the most failure-prone units.
Reduced wear
Changing liners, feed points and material flow.
Automation
Monitoring of load, drive currents, levels, vibration and equipment condition.
Important: the potential for higher throughput and lower wear is determined after analysing the flowsheet and the actual condition of the equipment — specific figures are given only based on project calculations.
/ Automation
Crushing and screening plant automation
Monitoring load, drive condition and process interlocks reduces downtime and emergency line stops.
Process interlocks
- Crusher overload
- Belt slip
- Chute blockage
- High bearing temperature
- High vibration
- Low oil pressure
- Emergency stop
Automation equipment
- PLC
- HMI
- VFD
- vibration sensors
- bearing temperature sensors
- level sensors
- belt scales
- control cabinet
Integration with the plant DCS
- Modbus RTU
- Modbus TCP
- PROFINET
- Ethernet/IP
What the operator sees on the HMI
PLANT LOAD
RUN- Feed
- 312 t/h
- Crusher 01
- 82%
- Screen 01
- RUN
- Crusher 02
- 74%
- Conveyor 03
- 68%
- Stockpile Level
- 61%
/ Installation supervision
Installation supervision
Technical supervision of equipment installation by specialists, checking correct assembly, installation and connection of main units.
- site readiness check
- installation control
- equipment position control
- connection check
- drive installation control
- piping connection control
- recommendations to the installation contractor
- preparing equipment for commissioning
/ START-UP
Commissioning
- 01
Installation check
- 02
Electrics and instrumentation check
- 03
Drive check
- 04
Idle run
- 05
Algorithm tuning
- 06
Start-up under load
- 07
Parameter adjustment
- 08
Handover of equipment to the customer
If provided for in the contract, training of the customer's staff.
/ Spare parts
Spare parts and consumables
- Crusher liners
- Vibration exciters
- Screen media
- Screen springs
- Conveyor idlers and pulleys
- Conveyor belt
- Bearing units
- Couplings and gearboxes
- Vibration and temperature sensors
- Control cabinet components
/ What to choose
Repair, upgrade or replacement?
Repair
When the equipment's original performance needs to be restored.
Goal: return the equipment to working order
Upgrade
When existing equipment is working or repairable, but its throughput, automation or operating characteristics need to change.
Goal: improve the existing system
Replacement
When remaining service life, structural condition or restoration cost make further repair economically unjustified.
Goal: replace the equipment with a new solution
/ How we work
How we handle a request
- 01
Request
We receive the problem description and documentation.
- 02
Analysis
We study the equipment and input data.
- 03
Audit
If needed, we inspect the equipment.
- 04
Solution
We define the scope of repair or upgrade.
- 05
Work
We carry out the agreed set of work.
- 06
START-UP
We test and adjust the equipment.
- 07
Operation
We hand over recommendations and the required documentation.
We work with equipment from other manufacturers
We carry out technical audits, repairs and selection of compatible components for crushing and screening equipment from various manufacturers once the model and technical parameters are identified.
Completed projects
Examples of completed inspection, repair and upgrade work are in the Projects section.
View projects/ Not sure where to start?
Send the equipment data and we will define the scope of work
The equipment passport, problem description, photos and technical parameters help engineers prepare a preliminary technical assessment.