Bergama 110 Series Crushing Plant: Every Fraction to Its Own Stockpile

Working footage of our 110 series crushing and screening plant in Bergama.

In the video the line is observed while running at full load. The run-of-mine material discharged into the hopper by the excavator passes through the vibrating feeder and descends to the primary crusher; the step-by-step reduction of the material on the conveyor belts can be followed.

The layout of the stockpile area is also visible in the footage.

Each fraction going to a separate pile prevents mixing during loading. The distance between the piles was left according to the manoeuvring area of the trucks.

Limestone quarries are widespread around Bergama; because the abrasiveness of the rock is low, wear part consumption stays behind that of hard stone.

Stages of the line

Run-of-mine material is discharged into the feed hopper by excavator or truck; the vibrating grizzly feeder directs the coarse fraction to the primary jaw crusher while bypassing the fines further down the line. The primary discharge goes to the secondary crusher and from there to the screening unit; oversize retained on the screen is returned in closed circuit to the tertiary or secondary crusher. Product fractions are carried to their own stockpiles by separate conveyors.

What determines the capacity

The catalogue figure of the 110 series line describes the output obtained with dry run-of-mine material of a suitable feed size and with uninterrupted feeding. Actual site output varies with moisture content, clay content, feed size distribution, how narrow the target fractions are and how much material is recirculated to the crusher in closed circuit. In wet and clayey material screening efficiency drops, so the same line runs at a lower tonnage; in that case a wet screening or washing stage is placed ahead of the line.

Operating notes

Keeping the tipping rhythm into the feed hopper steady prevents fluctuation in crusher current and the tonnage loss that follows it. Consumption of wear parts (jaw plates, blow bars, mantle and concave, screen mesh) depends on the abrasiveness of the rock and is the largest single item in operating cost. Regular lubrication, belt tension checks and monitoring the screen surface for blinding prevent the majority of unplanned stoppages.

Project-based solutions

Once you share the rock type, feed size and target fractions of your quarry, our engineering team prepares the flow diagram and the capacity calculation. You can review all line configurations on the products page and contact us through the contact page for a quotation. This scale is comfortably managed in a single shift in limestone quarries.