UNIQUEMAC 100TPH Granite Crushing and Screening Plant in Philippines Quarry

UNIQUEMAC has successfully designed, manufactured, and commissioned a complete 100TPH granite crushing and screening production line in the Philippines. This project was developed for a local quarry that processes high-hardness granite materials used in road construction, commercial concrete batching plants, and infrastructure development projects across the region.

Unlike conventional aggregate processing setups, this production line was specifically engineered to handle the extremely abrasive nature of Philippine granite, which typically contains high silica content and causes accelerated wear on crushing equipment. The entire system was designed with a focus on continuous production stability, reduced maintenance downtime, and optimized aggregate grading performance, ensuring that the customer could achieve long-term operational efficiency under demanding quarry conditions.

Project Background: Real Challenges in Granite Quarry Operations

The Philippine quarry involved in this project operates in a typical hard-rock mining environment where raw granite is blasted directly from mountain formations. The material characteristics are highly challenging for standard crushing systems due to large lump sizes, uneven fragmentation after blasting, and extremely high abrasiveness.

Before upgrading to the UNIQUEMAC system, the customer experienced several persistent operational problems. The existing production line frequently suffered from bottlenecks in the secondary crushing stage, where cone crushers were overloaded due to inconsistent feed from the primary jaw crusher. In addition, excessive wear on crusher liners and blow parts led to high operating costs and frequent shutdowns for maintenance.

Another major issue was unstable product gradation. The final aggregate output often contained excessive flaky particles and inconsistent size distribution, which did not fully meet the strict requirements of local highway construction standards. These limitations significantly reduced both production efficiency and product market value.

To address these challenges, UNIQUEMAC engineers conducted a full site analysis, including raw material testing, production capacity evaluation, and flow design simulation. Based on this data, a complete closed-circuit jaw–cone–screen system was proposed as the most suitable solution for achieving stable 100TPH output under hard granite conditions.

Engineering Design: 100TPH Crushing and Screening Configuration

The complete production system was carefully configured to ensure balanced crushing efficiency across all stages of processing. Each machine was selected not only based on capacity but also based on compatibility with granite hardness and expected wear resistance requirements.

The main equipment includes:

• GZT0724 vibrating feeder for controlled raw material feeding
• PE5075 jaw crusher as the primary crushing unit
• PYB900 spring cone crusher for secondary and fine crushing
• 4YK1548 multi-deck vibrating screen for precise aggregate classification
• Heavy-duty belt conveyor system for continuous material transport

This configuration ensures a stable material flow from the initial feeding stage to the final screening process. The system is designed as a closed-loop circuit, meaning oversized materials are automatically returned to the cone crusher for reprocessing. This design significantly improves crushing efficiency and ensures that the final product consistently meets the required grading standards.

Detailed Working Process of the Crushing Plant

The entire production process begins with the GZT0724 vibrating feeder, which plays a critical role in regulating the flow of raw granite into the system. By evenly distributing large and irregularly shaped blasted rocks, the feeder prevents sudden load fluctuations that could negatively impact the performance of the primary crusher. This step is essential for maintaining stable downstream operation.

Once the material is evenly fed, it enters the PE5075 jaw crusher, where primary crushing takes place. At this stage, large granite blocks are broken down into medium-sized aggregates through high compressive force. The jaw crusher is specifically designed to handle extremely hard rock, ensuring high reduction efficiency even under continuous heavy-duty operation.

After primary crushing, the material is transported to the PYB900 cone crusher. This stage is responsible for secondary and fine crushing, where the material is further reduced into smaller, more uniform particles. The cone crusher design allows for better shaping of aggregates, reducing flakiness and improving the overall quality of the final product.

Finally, the crushed material is sent to the 4YK1548 vibrating screen, which separates the aggregates into different size fractions according to construction standards. Oversized particles that do not meet the required specifications are automatically returned to the cone crusher for re-crushing, forming a continuous and efficient closed-loop production system.

On-Site Performance and Operational Stability

After installation, commissioning, and trial operation completed by UNIQUEMAC’s engineering team, the production line quickly reached its designed capacity of 100 tons per hour. More importantly, the system demonstrated excellent operational stability even under continuous long-hour production conditions.

One of the most significant improvements observed was the reduction in unplanned downtime. Compared to the customer’s previous setup, the new system showed a marked decrease in blockages at the feed and crushing stages. This improvement is mainly attributed to the balanced design of the feeder and crusher combination, which prevents overload conditions.

In addition, the wear cost of consumable parts such as jaw plates and cone liners was significantly reduced due to optimized crushing chamber design and improved material flow distribution. The final aggregate product also showed more consistent particle size distribution, which increased its market acceptance and allowed the quarry to supply higher-value construction projects.

Turnkey Project Execution and Engineering Support

UNIQUEMAC provided a complete turnkey solution for this project, covering every stage from initial planning to final production handover. The engineering team was responsible for site layout planning based on terrain conditions, equipment selection according to material characteristics, and full production line integration.

During installation, UNIQUEMAC technicians provided on-site guidance to ensure correct assembly of all mechanical and electrical components. After installation, the commissioning phase included full system testing, load adjustment, and operator training to ensure the customer’s team could independently manage daily operations.

Even after project completion, UNIQUEMAC continues to provide technical support and spare parts service, ensuring long-term stable operation of the production line.

Customer Feedback and Project Outcome

After several months of continuous operation, the Philippine customer reported that the new crushing system has significantly improved overall quarry productivity. The production line not only achieved the expected 100TPH capacity but also maintained stable output quality under varying feed conditions.

The customer particularly highlighted the reduction in maintenance frequency and the improved durability of wear parts. These improvements directly contributed to lower operational costs and higher profitability per ton of produced aggregate.

The success of this project has further strengthened long-term cooperation between both parties and demonstrated UNIQUEMAC’s capability in delivering reliable crushing solutions for hard rock applications in Southeast Asia.

About UNIQUEMAC

UNIQUEMAC is a professional manufacturer specializing in crushing, screening, and aggregate processing equipment. With extensive experience in global mining and quarry projects, the company provides customized solutions for various hard rock applications including granite, basalt, limestone, and river stone processing.

Our product range includes jaw crushers, cone crushers, vibrating feeders, vibrating screens, and complete crushing plant systems. These machines are widely used in infrastructure construction projects across Southeast Asia, the Middle East, Africa, and South America.

FAQ

Q1: Is a 100TPH crushing plant suitable for commercial quarry operations?
Yes, a 100TPH production line is ideal for small to medium-scale quarries that require stable aggregate output for local construction markets.

Q2: Why is a jaw and cone crusher combination widely used for granite?
Because granite is extremely hard and abrasive, the jaw crusher handles primary breaking while the cone crusher ensures better shaping and higher efficiency in secondary crushing.

Q3: How does a closed-circuit crushing system improve efficiency?
A closed-circuit system allows oversized material to be reprocessed automatically, ensuring