Summary: This flagship demonstration project is located in Jakarta, Indonesia. Adopting centralized modular layout, intelligent control and closed‑circuit cone‑crushing technology, the plant achieves a 450‑500 TPH hard‑rock aggregate production capacity with lower capital investment, reduced energy consumption and compact site footprint....
1.Project Overview
Located in Jakarta, Indonesia, the project is designed with a capacity of 450–500 t/h to process hard rock. The final product covers a precise continuous grading of 0–5–10–20–30 mm, fully meeting the aggregate standards for construction in Indonesia and neighboring markets countries. Designed and built as a regional demonstration project, it strictly adheres to industrial, eco-friendly, modular, and intelligent requirements.
| Item | Specifications |
|---|---|
| Raw Material | Mountain rock, hard stone |
| Feed Size | 0-800mm |
| Output Size | 0-5-10-20-30mm |
| Capacity | 450-500t/h |
| Installation | Stationary |
| Product Standard | Meets Indonesian and neighboring countries' aggregate standards for construction |
| Main Equipment | F5X1654G ×1 + C6X125 ×1 + HST250S ×1 + HST250H ×2 + S5X2760-2 ×2 + S5X2160-2 ×3 |
2.Key design innovations of this crushing plant
2.1Centralized Modular Secondary & Tertiary Layout for Cost Reduction and Efficiency
By grouping the HST250S secondary cone crusher and HST250H tertiary cone crushers within one centralized modular control zone, the design drastically cuts steel‑structure demand and belt‑conveyor length required for cross‑zone material transfer in conventional layouts.
This consolidated arrangement improves overall material‑transfer efficiency, minimizes plant footprint and lowers comprehensive operational energy consumption.
2.2 Topography-Assisted Grading & Optimized Electrical Controls
The site features three stepped elevation tiers. Equipment is arranged to leverage natural gravity drop, reducing power consumption for vertical material lifting.
Two independent control rooms are deployed for the primary-crushing zone and the combined secondary-tertiary crushing-screening zone respectively. Locating the main control room adjacent to the high-power-demand mid-stream section shortens main-cable routing, reducing CAPEX investment and power-transmission losses.
3.Crushing Process Workflow
The project utilizes a "three-stage crushing + closed-circuit screening" process to accommodate high reduction ratios while optimizing finished product shape.
3.1Primary Crushing & Pre-Screening
Raw materials are discharged from dump trucks into the feed hopper and fed uniformly by a heavy-duty vibrating grizzly feeder (F5X1654G). Fine material smaller than 120 mm is screened out beforehand and enters a pre-screening machine (S5X2160-2) to separate the 0–10 mm soil and debris, while large rocks exceeding 120 mm are fed directly into a C6X125 jaw crusher for primary crushing.
3.2 Secondary Crushing and Buffer Transfer
Material larger than 10 mm from the pre-screening stage and the coarse product from the jaw crusher are fed into a buffer bin. They are then conveyed to an HST250S single-cylinder hydraulic cone crusher for secondary crushing, rapidly reducing the material to a particle size range of approximately 0–70 mm.
3.3 Grading Screening and Closed-Circuit Fine Crushing
The material undergoes multi-layer classification via vibrating screens (S5X2760-2 and S5X2160-2) to precisely separate finished products into 0–5 mm, 5–10 mm, 10–20 mm, and 20–30 mm aggregates, which are then sent to the finished product storage bin. Aggregates larger than 31 mm are temporarily stored in a steel-structure transfer bin before entering two sets of HST250H fine-crushing cone crushers for closed-circuit crushing until they meet the required specifications.
4.Why This Configuration Fits Southeast Asian Hard Rock Projects
4.1 High-Moisture & High-Clay Material Handling
The grizzly feeder pre-screens and removes sticky muck before primary crushing, preventing chamber clogging—a essential design feature for tropical climates like Jakarta.
4.2 Multi-Specification Output Flexibility
Five vibrating screens operate in parallel to simultaneously and efficiently produce four standard product sizes: 0–5–10–20–30 mm, flexibly meeting the diverse demands of road construction, concrete mixing.
4.3 HST Single-Cylinder Cone Crusher Advantages
The HST series cone crusher features convenient discharge opening adjustment and a high reduction ratio, demonstrating exceptional stability when processing hard rock. Parallel operation of two units in the tertiary crushing stage provides the system with high capacity and solid reliability.
As a regional showcase project, it provides a proven, highly replicable blueprint for investors planning aggregate production lines in Indonesia and Southeast Asia.
If you are planning to set up a cost-effective crushing production line, or wish to learn more about SBM’s projects in Indonesia and around the world, please feel free to contact our senior system engineers for customized solutions and technical support.
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