Scaling operations up to 100 TPH (Tons Per Hour) represents a major milestone for quarry operators aiming to supply major infrastructure, NHAI highway projects, and high-volume commercial ready-mix concrete plants. At this capacity level, single-stage crushing becomes inefficient; therefore, a highly balanced primary-secondary or primary-secondary-tertiary circuit is mandatory. This guide highlights SREW's technical configuration, complete cost structures, and plant space parameters for a high-performance 100 TPH plant.
1. Standard SREW 100 TPH Turnkey Plant Configuration
A balanced 100 TPH quarry plant configuration requires highly durable wear-resistant steel castings and rigid primary structures. The standard SREW-designed loop consists of:
- Primary Station: Heavy duty Grizzly Feeder GF-1000 x 3800 feeding an SREW JS-3015 Heavy-Duty Jaw Crusher (max feed size 500mm).
- Secondary Station: High-efficiency SREW Hydraulic Cone Crusher Model S-1200 or HSI-1010 Impact Crusher (depending on feed material abrasiveness).
- Screening Section: SREW 4-Deck High Amplitude Vibrating Screen (VS-1548) separating 4 distinct commercial sizing output streams.
- Conveyor Logistics: Heavy channel belt conveyor grid with a standard width of 800mm for high volume transport.
2. 100 TPH Project CAPEX Breakdown Table
This table details typical machinery and setup costs for an SREW 100 TPH crushing setup. Civil construction costs (concrete columns, control room building) and electrical power lines are estimated separately.
| Machinery Component | Technical Specifications | Estimated Cost (INR Lakhs) |
|---|---|---|
| Primary Hopper & Feeder | 6m³ reinforced hopper + GF-1000 x 3800 Grizzly | ₹8.80 L |
| SREW Primary Jaw Crusher | Model JS-3015 (Feed opening 750x375mm) | ₹22.50 L |
| Secondary Cone Crusher | Model S-1200 (Hydraulic automation, 110 kW) | ₹38.00 L |
| SREW Vibrating Screen | Model VS-1548 (4-Deck, 1.5m x 4.8m) | ₹12.20 L |
| Conveyor Belt Grid (6 Lines) | Width 800mm, heavy-duty channel frame | ₹8.40 L |
| PLC Automation & Cabling | Intelligent PLC control center + copper cabling | ₹6.50 L |
| Turnkey SREW Machinery Cost | EPC OEM Sizing | ₹96.40 Lakhs |
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