100 TPH Limestone Crushing Plant In New Zealand

Client Background

A leading construction materials supplier in New Zealand sought a reliable partner to establish a 100-ton-per-hour limestone crushing line for producing high-quality sand and aggregates. Their primary challenges included hard rock abrasiveness, strict particle shape requirements, and the need for an energy-efficient system.

Project Overview

• Material: Limestone (compressive strength: ~120MPa)
• Feed Size: ≤500mm
• Output: 0-5mm (sand), 5-20mm, 20-40mm aggregates
• Capacity: 100TPH
• Location: North Island, New Zealand

Challenges

1. Abrasive Wear: Limestone’s hardness demanded wear-resistant equipment.
2. Grain Shape: Local building codes required cubical aggregates for concrete.
3. Space Constraints: Compact plant layout needed for mountainous terrain.

Solution: Liming Heavy Industry’s Customized Crushing Line

1. Primary Crushing – C6X Jaw Crusher

• Model: C6X125
• Role: Coarse crushing of ≤500mm limestone blocks.
• Advantage: Reinforced frame, optimized crushing cavity, and 25% longer service life than conventional jaws.

2. Secondary Crushing – HST Single-Cylinder Hydraulic Cone Crusher

• Model: HST160
• Role: Precise intermediate crushing to produce 20-40mm & 5-20mm aggregates.
• Advantage: Fully automated hydraulic adjustment reduces downtime by 30%.

3. Tertiary Shaping & Sand Making – VSI6X Sand Maker

• Model: VSI6X1263
• Role: Producing 0-5mm sand with >60% sphericity for premium concrete.
• Advantage: Four-port rotor design increases throughput by 20% while reducing energy consumption.

4. Auxiliary Equipment

• Vibrating Feeder: ZSW490×110 (ensures even feeding).
• Circular Vibrating Screen: S5X2460-2 (3-deck screening for precise grading).
• Dust Suppression System: Minimizes environmental impact.

Technical Highlights

• Smart Control System: Centralized PLC automation monitors production in real time.
• Modular Design: Pre-assembled modules reduced on-site installation time by 40%.
• Eco-Friendly: Noise <75dB, dust emissions below NZS 6803:1999 standards.

Results

• Output: Exceeded target at 105TPH with 95% uptime.
• Product Quality: Sand achieved MB≤10 (low clay content), aggregates met NZS 3121:1986.
• ROI: Client recouped costs in 14 months due to low maintenance expenses.

Client Feedback

“Liming’s team delivered beyond expectations. The VSI6X’s sand yield saved us 15% on cement costs, and their remote diagnostic service is invaluable.”
— Quarry Operations Manager, New Zealand