In the sand and gravel aggregate industry, a production line with an output of 100-150 tons per hour is a typical “medium-sized” configuration. This capacity range not only meets the normalized demand for sand and gravel aggregates in the regional market, but also avoids the high investment and complex management of large production lines, and has become the preferred solution for many private enterprises, mixing plant supporting projects and regional mine development. As a manufacturer of mine crushing and grinding equipment with 50 years of experience, we deeply understand the core demands of customers of this magnitude of “moderate investment, stable returns, and simple operation”. The 100-150t fixed production line has become a highly competitive scale choice in the sand and gravel aggregate market with its mature process configuration, stable operation performance and excellent economic benefits.

What is a 100-150t fixed production line?

100-150t fixed production line refers to a stationary crushing and screening combined unit with a design processing capacity of 100-150 tons per hour. This capacity scale can not only meet the daily production needs of small and medium-sized sand and gravel yards, but also serve as a supporting raw material supply system for large-scale concrete batching plants and dry mix mortar production lines. Compared with mobile stations, fixed production lines have the characteristics of lower investment, more stable production capacity and simpler maintenance, making them ideal for long-term operation projects.

Core composition and applicable materials

 
A typical 100-150t stationary production line typically includes:

• Feeding system: vibrating feeder (e.g. ZSW960×3800)
• Coarse crushing system: jaw crusher (e.g. PE600×900)
• Medium and fine crushing system: Counter-breaking or cone breaking can be selected according to the hardness of the material
• Screening system: multi-layer vibrating screen (e.g. 4YK1860)
•  Conveyor system: multiple belt conveyor
• Control system: centralized electronic control system

The production line can handle a wide range of materials, including limestone, granite, basalt, river pebbles, iron ore, construction waste, etc., the feed particle size is generally required ≤ 1000mm, and the finished product can produce 0-5mm, 5-10mm, 10-20mm, 20-40mm and other specifications of aggregates according to demand.

The three mainstream configuration schemes of 100-150t fixed production lines

Scheme 1: Hard rock crushing scheme (jaw breaking + cone breaking)

For high-hardness materials such as granite, basalt, river pebbles (compressive strength ≥ 200MPa), it is recommended to use the classic configuration of “jaw crusher + cone crusher”.

Process flow: The large stone is uniformly fed into the jaw crusher by the vibrating feeder through the silo for coarse crushing, the coarsely crushed material enters the cone crusher for fine crushing, and the crushed material is graded by the vibrating screen to screen out the finished aggregate of different specifications.

Solution advantages: Cone crushing adopts the principle of lamination crushing, long wear parts life, stable operation, especially suitable for long-cycle production of high hard materials.

Scheme 2: Soft rock crushing scheme (jaw breaking + counterattack breaking)

For limestone, dolomite, gypsum and other materials of medium hardness and below (compressive strength ≤ 150MPa), it is recommended to use the configuration of “jaw crusher + impact crusher”.

Advantages of the scheme: the counter-breaking adopts the principle of impact crushing, the finished product has excellent particle shape, high cube content, low needle flake content, and the investment cost is lower than that of the cone breaking scheme.

Scheme 3: Sand production line scheme (jaw breaking + cone breaking + sand making machine)

When the project needs to produce crushed stone and machine-made sand at the same time, the three-stage crushing scheme of “jaw crushing + cone crushing + sand making machine” can be adopted.

Finished product specifications: It can produce 0.25-0.35mm fine sand, 0.35-0.5mm medium sand, 0.5mm coarse sand and other specifications.

Scheme advantages: The sand making machine adopts the principle of “stone beating stone” or “stone hitting iron”, and the finished sand particle shape is round, the gradation is excellent, and the value is higher. The year-on-year energy consumption is reduced by more than 15%, and with the high-efficiency dust removal device, green and environmentally friendly production is realized.