200t/h Limestone Crusher Plant in Malaysia

About 200TPH Limestone Crusher Plant – From Quarry to High-Value Aggregates

Malaysia's robust construction and infrastructure development demand a steady supply of high-quality aggregates. Limestone, being a common and versatile resource, is a primary raw material for these projects. However, transforming raw limestone into precisely graded aggregates and high-quality manufactured sand (M-Sand) requires a sophisticated and efficient crushing circuit. Our Malaysia clients sought to establish a high-capacity plant specifically designed to process limestone into premium products for concrete, asphalt, and infrastructure projects. We designed and provided this three-stage crushing circuit plant, capable of producing a variety of aggregate sizes and premium manufactured sand to meet market needs.

● Raw Material: Local limestone (low silica content, 2–3% moisture, no sticky clay—easy to crush).
● Production Goal: 200 TPH of multi-grade products: 0–5mm sand (for mortar), 5–10mm fine aggregate (concrete), 10–20mm coarse aggregate (road base), 20–40mm aggregate (structural concrete).
● Crushing plant process: 3-stage crushing (primary: jaw crusher → secondary: impact crusher →Vibrating sceen → tertiary: VSI sand maker) + Vibrating screening.

The Equipment Solution: A Detailed Breakdown of the 3-Stage Stone Crushing Plant

The proposed solution by Baichy Machinery is a well-proven configuration consisting of a primary jaw crusher, a secondary fine jaw crusher, and a multi-layer vibrating screen. This setup is designed for optimal performance and product control.

1. Vibrating Feeder: ZSW1142

● Function: As the plant's entry point, this heavy-duty feeder regulates the flow of raw limestone (up to 500mm) from the hopper to the primary crusher. Its key role is to ensure a consistent and stable feed, preventing choke-feeding and maximizing the overall efficiency of the entire production line.

2. Primary Jaw Crusher: PE750x1060

● Function: This robust crusher handles the primary size reduction. It crushes the large, raw limestone boulders into smaller, manageable stones (around 150-200mm).
● Key Features: Known for its reliability and high crushing ratio, the PE750x1060 provides a solid foundation for the subsequent stages. Its sturdy structure is built to withstand the high-impact forces of primary crushing.

3. Secondary Impact Crusher: PF1315

● Function: Taking the output from the jaw crusher, the PF1315 performs secondary crushing. It further reduces the stone size and, crucially, begins to shape the aggregate. Impact crushers are excellent for producing a well-graded, cubical product.
● Key Features: The PF1315 is a large model with a high capacity and strong crushing force, ideal for medium-hard rocks like limestone. It produces excellent aggregate shape for use in high-specification concrete.

4. Tertiary/Sand Making Crusher: VSI1145

● Function: This is the final stage for shaping and sand manufacturing. The VSI (Vertical Shaft Impact) crusher uses a "rock-on-rock" or "rock-on-iron" crushing principle to refine the aggregate and produce high-quality, cubical manufactured sand from the finer fractions.
● Key Features: The VSI1145 ensures the final products have superior particle shape. It is the key machine for producing sand that meets national standards, effectively controlling the fineness modulus and removing flaky and elongated particles.

5. Screening Station: 2 Units of 4YK1237 Vibrating Screens

● Function: These two 4-layer vibrating screens are the control center for product classification. They precisely separate the crushed material into multiple final product specifications (e.g., 0-5mm sand, 5-10mm, 10-20mm, and 20-31.5mm aggregates).
● Key Features: The use of two screens allows for high screening efficiency and capacity. Oversized material is recirculated back to the appropriate crushers (PF1315 or VSI1145), forming a closed-circuit system that ensures no stone is wasted and all product sizes are perfectly controlled.

6. Belt Conveyors

● Function: A network of belt conveyors acts as the plant's circulatory system, seamlessly connecting all the equipment—from the feeder to the crushers, between the screens, and finally to the product stockpiles.
● Key Features: They are designed for durability, minimal material spillage, and smooth operation, which is critical for maintaining a continuous 200TPH output.

Key Advantages of Combined Mobile Limestong Crusher Plant

1. High Automation & Efficiency: The plant requires minimal manual intervention, ensuring consistent output and reducing labor costs. The closed-circuit design with two screens maximizes production yield.

2. High Automation & Efficiency: The plant requires minimal manual intervention, ensuring consistent output and reducing labor costs. The closed-circuit design with two screens maximizes production yield.

3. Comprehensive Product Range: The plant can simultaneously produce up to 4-5 different sizes of high-quality aggregates and sand, allowing the quarry owner to cater to various market demands and maximize profitability.

4. Robustness and Reliability: The selected equipment models are industry-proven for their durability and performance in processing abrasive materials like limestone, ensuring long-term operational uptime.

Baichy Machinery Service Support in Malaysia

Crushing Solutions Design

Baichy Machinery can customize a crushing plant for you based on the specific conditions of your project: such as the construction site, hardness of the raw materials, output, output size, budget, etc.

On-site Installation & Training

Our team provides on-site installation and thorough training to ensure safe operation of the crushing plant.

Quality Control & Global Delivery

Rigorous quality checks ensure compliance with standards, and we handle worldwide delivery to your location.

After-Sales Support

Baichy Machinery provides you with spare parts supply, project transformation, investment return analysis, etc.

Crushing Solutions Design

On-site Installation & Training

Quality Control & Global Delivery

After-Sales Support

Frequently Asked Questions (FAQs)

Find answers to the most common questions about Baichy Machinery. If you can’t find what you’re looking for here, please contact us.

1. Why is a three-stage crushing circuit necessary?

A three-stage circuit allows for precise control over the final product's size and shape. The jaw crusher does the heavy lifting, the impact crusher improves the shape and reduces size further, and the VSI crusher perfects the shape and creates sand. This results in higher-value products compared to a simpler one or two-stage setup.

2. Why choose an Impact Crusher instead of a Cone Crusher?

Limestone is a medium-hardness rock. Impact crushers are highly effective for such material, offering a better cost-performance ratio, higher production capacity, and, most importantly, superior product shape compared to cone crushers, which is critical for high-grade concrete aggregates.

3. How is the dust control managed in the plant?

Dust is a major challenge. This plant is equipped with a comprehensive dust suppression system, including water sprays at key transfer points (like crusher inlets and screen decks) and the option to fit baghouse filters for a cleaner, environmentally compliant operation.

4. What are the key maintenance points for such a large plant?

Key maintenance focuses on wear parts. Regular inspection and replacement of jaw plates (PE750x1060), impact blow bars (PF1315), and rotor tips/anvils (VSI1145) are essential. Additionally, maintaining conveyor belt integrity, checking screen mesh for clogging or damage, and ensuring all vibrators and bearings are properly lubricated are critical for preventing unplanned downtime.

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