NEO MAKİNA ve MÜHENDİSLİK A.Ş. builds turnkey crushing and screening plants for quarries and aggregate producers. Modular plants comprising grizzly feeder, primary jaw crusher, secondary/tertiary cone or impact crusher, VSI sand maker, multi-deck vibrating screens, conveyors and washing units produce concrete and asphalt aggregates to EN 12620 at 50–1,000+ t/h in fixed or mobile configuration.
Process Flow
1. Feeding and Primary Crushing
- Grizzly feeder: Blasted run-of-mine material is tipped into the hopper; grizzly bars scalp fines (bypass soil) and raise crusher capacity by 20–30%.
- Primary jaw crusher: Rock up to 1,000 mm reduced below 150–200 mm; hydraulic setting and overload protection.
2. Surge Storage
- Primary product goes to a surge hopper or tunnel stockpile; primary stoppages do not halt the plant.
- Level sensors regulate secondary feed; choke feeding improves cubicity and liner life.
3. Secondary and Tertiary Crushing
- Metal detector and magnetic separator: Protect crusher internals.
- Cone crusher: Low fines and high-quality chippings on hard, abrasive rock such as granite and basalt.
- Impact crusher (HSI): High reduction ratio and cubic product on medium-hard limestone and dolomite.
- VSI (vertical-shaft impactor): Sand production and shaping; 0–5 mm crushed sand.
4. Screening and Classification
- 3–4 deck inclined or horizontal vibrating screens; polyurethane or wire-mesh decks; 0–5, 5–12, 12–22, 22–32 mm and custom fractions.
- Adjustable amplitude and inclination for blinding-free screening of damp material; optional deck spray nozzles.
5. Closed Circuit and Stockpiling
- Oversize from the top deck returns to the tertiary crusher via a recirculation conveyor; every fraction leaves at standard size.
- Separate stockpiles via stacking conveyors; radial stacker and bin-loading options.
- Washing (optional): Spiral sand washer, dewatering screen, cyclone and hydrocyclone; water recovery with filter press.
Plant Types and Capacity
- Fixed modular plants: 100 – 1,000+ t/h on steel structures for long-life quarries; 2- or 3-stage.
- Mobile and portable plants: Wheeled or tracked chassis; fast mobilisation for construction sites and short-term projects; 50 – 300 t/h.
- Stage selection: Single stage (fill material), two stages (standard chippings), three stages + VSI (high-quality sand and asphalt aggregate).
Technical Basis
- Material analysis: Crusher type and stages selected from compressive strength, Los Angeles abrasion value, abrasion index, moisture and clay content.
- Mass balance: Product-curve simulation calculates tonnage per fraction and circulating load; screen area and conveyor capacities follow.
- Wear management: Manganese jaw and cone liners, chrome-cast blow bars, Hardox chute liners; easy replacement.
- Dust and noise control: Enclosed chutes, water spray or bag filter at transfer points; acoustic crusher enclosures.
- Automation: Sequenced start/stop, crusher load and hopper level control, belt-scale production tracking, SCADA and remote monitoring.
- Standards: CE Machinery Directive, EN 1009 (mineral-processing safety), EN 12620 (concrete aggregates), EN 13043 (asphalt aggregates)
Why NEO MAKİNA?
The plant is delivered from a single source, from quarry survey and product target through mass balance, layout, steel structure, electrical-automation and erection. Capacity upgrades, stage additions (VSI, washing) and crusher replacement are carried out at existing plants. See Industrial Crusher Systems for crusher types and Mineral Crushing and Screening Plants for mining applications.
Frequently Asked Questions
Cone or impact crusher?
On hard, abrasive rock (granite, basalt, quartzite) the cone crusher gives low wear cost; on limestone and dolomite the impact crusher gives higher cubicity and reduction ratio.
Fixed or mobile plant?
With quarry life above 5 years and capacity above 200 t/h, a fixed plant is cheaper per tonne; mobile plants suit short-term projects and recycling sites.
How long does installation take?
For a 200 t/h fixed plant, engineering and manufacturing take 3–4 months, site erection and commissioning 2–3 months; mobile plants are commissioned within days of delivery.
For plant design and a quotation based on your quarry material and target products, contact us.