FULLSTAR-90
Semi-Mobile Crushing Screening and Washing Plant
Technical Information
| Production Capacity | 120–180 Tons/Hour |
| Vibrating Screen Size | 1550×4000 mm – 1700×4500 mm |
| Screw Washer Dimensions | Ø600 x 5000 mm (Double Helix) |
| Jaw Crusher Feed Opening | 900×650 mm |
| Secondary Crusher Model | Secondary Impact Crusher |
| Maximum Feed Rate | 600 mm |
| Total Engine Power | 380 kW |
| Generator *Optional | 450 kVA |
| Separator Belt *Optional | 800 mm |
| Shipping Dimensions | 1. Chassis: Length: 19,000 mm Width: 4,000 mm Height: 4,500 mm 2. Chassis: Length: 16,000 mm Width: 4,500 mm Height: 4,400 mm |
FULLSTAR-90 Semi-Mobile Crushing Screening and Washing Plant
FULLSTAR-90 The Semi-Mobile Crushing Screening and Washing Plant, with a production capacity of 120–180 Tons/Hour, performs primary crushing, secondary impact crushing, screening, and washing operations on two separate chassis. The first chassis, equipped with a jaw crusher capable of handling feed sizes up to 600 mm, performs the primary crushing and washing operations, while the second chassis handles the secondary impact crushing and screening processes.
In the first chassis Feeding BunkerThe rock is fed into the jaw crusher via a vibrating feeder. After primary crushing, the material is directed to a 1700 x 4500 mm vibrating washing screen, where it is washed and classified by size. The finest material obtained during screening is transferred to a Ø600 x 5000 mm Screw Washer, where it is cleaned. Products of other sizes are transported to the stockpile area via side conveyor belts. The coarse material remaining on the screen is transferred to the second frame for further crushing.
In the second stage, the material is fed into a secondary impact crusher and reduced to smaller sizes. The crushed material is transferred to a 1550 x 4000 mm vibrating screen and classified according to particle size. The coarse material remaining on the screen is returned to the secondary impact crusher for further crushing. Thanks to this closed-circuit operating principle, the material undergoes crushing and screening until it reaches the desired size. The screening process in the second stage is performed without washing; washing operations are carried out via the wash screen and the twin-screw washer in the first stage.
With a total engine power of 380 kW FULLSTAR-90, it can be configured to meet various operational needs with an optional 450 kVA generator system and an 800 mm separator. Its dual-chassis design allows the primary crushing and washing line and the secondary crushing and screening line to be transported as separate units. Thanks to these two complementary lines, FULLSTAR-90, combines the production of aggregate in various sizes and the washing of fine material into a single integrated system.
Features
- Wide Range of Feeding Options
Feeding bunkers can be loaded using excavators, trucks, and loaders. This design provides operational flexibility in construction site and quarry applications where different loading equipment is used. - Flexible Feeding Bunker Design
Feeding Bunker Capacity can be determined based on the required capacity in accordance with the machine’s current design. - Controlled Feeding System
Thanks to the manual speed control on the feeder, the amount of material fed into the crusher can be adjusted according to operating conditions and production needs. - Hydraulic System
Conveyor belts and hopper hatches can be easily folded and unfolded using the hydraulic system. This design allows for the rapid transportation and installation of the semi-mobile crushing and screening plant without the need for a crane. *Optional - Front Flap
In applications requiring the production of a single product type, the optional front flap located in front of the screen feed belt prevents the material from being transferred to the vibrating screen, allowing the product to be directed directly to the front storage belt. *Optional - Transportation with a Single Truck Head
Thanks to its semi-mobile design, all of the facility’s equipment can be transported using a tow truck. This feature helps streamline logistics operations between different work sites. - Easy Maintenance and Lubrication
Thanks to the manual grease fittings, periodic lubrication of moving components can be easily performed.
An automatic lubrication unit can be installed to extend maintenance intervals. *Optional - Precision Final Product Adjustment
– Jaw Crusher Discharge Opening: The outlet opening of the jaw crusher can be adjusted manually and can be adjusted quickly and easily using the optional hydraulic adjustment system.
– Secondary Impact Crusher Discharge Opening: The discharge opening of the secondary impact crusher can be adjusted quickly and easily using a manual hydraulic adjustment system.
– Automatic Final Product Size Adjustment: For both crushers, the crushing gap can be automatically adjusted based on the value entered into the automation system. This allows for quick and precise control of the final product size. *Optional - Vibrating Wash Screen
A vibrating wash screen not only classifies the material but also subjects it to a washing process. The washing nozzles located on each layer of the screen remove unwanted fine particles and contaminants from the material. - Screw Washer
A twin-screw washer is used to aid in the cleaning of fine material that passes through the washing screen. The screw system helps guide the fine material through the washing process, thereby improving product cleanliness. - Braked Axle System
A braked axle system is used to ensure that the semi-mobile crushing and screening plant can be transported safely. - Low-Maintenance Platforms
Thanks to maintenance platforms that facilitate access to areas requiring maintenance, service and inspection procedures can be carried out more safely and conveniently. *Optional - Fully Automatic Automation System
The PLC-based automation system can be managed via an HMI touchscreen panel and remote tablet control. This allows for centralized monitoring of the crushing and screening process. - Generator System
Thanks to the generator system, the facility can be powered by diesel fuel at construction sites where there is no electrical infrastructure. *Optional - Windshifter Technology
The Windshifter, which can be positioned on a long return conveyor, helps separate unwanted lightweight materials from the material on the screen using an airflow. This improves the cleanliness of the final product. *Optional - Minimum Infrastructure Requirements
Thanks to its semi-mobile design, the facility requires minimal infrastructure for installation. The necessary technical information and guidance are provided during the installation process.
Technical Specifications
| Capacity: | 18 m³ *Standard | 25 m³ *Optional |
| Feeding Height 18 m³: | 5250 mm |
| Feeding Height 25 m³: | 5250 mm |
| Bunker Material Thickness: | 15 mm |
| Protective Lining Material: | ST52 *Standard / Wear-Resistant 450 HBW Plate*Optional |
| Protective Coating Thickness: | 10 mm |
| Hydraulically Controlled Bunker Hatches: | *Optional |
| Feeder Width: | 1050 mm |
| Body Protection Liner: | Wear-Resistant 450 HBW Plate |
| Number of Vibration Motors: | 2 |
| Vibration Motor Power: | 2×4,5 kW |
| Manual Speed Control: | Included |
| Grill Spacing: | This can be determined based on customer requests. |
| Movable Jaw Thickness: | 125 mm |
| Movable Jaw Bedding Unit Material: | G20Mn5 Cast Steel |
| Body Thickness: | 50 mm |
| Fixed Jaw Thickness: | 100 mm |
| Protective Coating Thickness: | 25 mm |
| Protective Liner Type: | Bolted |
| Automatic Lubrication System: | Optional |
| Braked Axle System: | Included |
| Warning and Signaling System: | Included |
| Floor-by-Floor Cleaning System: | Included |
| Engine Configuration: | Single-Engine |
| Shaft Configuration: | Belt and Pulley |
| mesh Mesh Tensioning System: | Bolted |
| Body Material: | ST52 |
| Protective Primers: | Included |
| Inlet Channel Protective Lining Material: | Wear-Resistant 450 HBW Plate |
| Thickness of the Inlet Channel Protective Liner: | 10 mm |
| Automatic Lubrication System: | Optional |
| Pallet Thickness: | 110 mm |
| Pallet Material: | 16%–18% Manganese Cast Steel |
| Bedding: | G20Mn5 Cast Steel |
| Automatic Lubrication: | Optional |
| Pendulum Materials: | 16%–18% Manganese Cast Steel |
| Pendulum Thickness: | 80 mm |
| Body Protection Liner Thickness: | 35 mm |
| Body Protection Lining Material: | 12%–14% Manganese Cast Steel *Standard / Wear-Resistant 450 HBW Plate*Optional |
| Body Protection Liner Type: | Bolted |
| Hydraulic Housing: | Included |
| Inspection Cover: | Included |
| Engine Configuration: | Single-Engine |
| Shaft Configuration: | Belt and Pulley |
| mesh Mesh Tensioning System: | Bolted |
| Body Material: | ST52 |
| Protective Primers: | Included |
| Inlet Channel Protective Lining Material: | Wear-Resistant 450 HBW Plate |
| Automatic Lubrication System: | Optional |
| Engine Power: | 2 x 7,5 kW |
| Gearbox Type: | Pear-Shaped Helical Gear Reducer |
| Drive Mechanism: | Belt-Pulley Drive |
| Braked Axle System: | Included |
| Warning and Signaling System: | Included |
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