Featured Project
RAJASTHANZINC
CRUSHING PLANT
500 TPH Crushing & Screening Solution
A robust and high-performance crushing system designed to deliver consistent output, maximum efficiency, and long-term reliability in demanding mining conditions.
500 TPH
Plant Capacity
98%
Plant Availability
35%
Increase in Productivity
24/7
Continuous Operation
End-to-End
Solution Delivered
Lifetime
After-Sales Support
Executive Summary
This project was executed to deliver a high-performance crushing and screening solution for zinc ore processing with maximum efficiency, reliability, and minimal downtime.
Client Industry
Mining Industry
Zinc Ore Processing
Location
Udaipur, Rajasthan
India
Plant Capacity
500 TPH
Crushing & Screening Plant
Material Type
Zinc Ore
Up to 400mm Feed Size
Project Duration
14 Months
Design to Commissioning
Machines Supplied
4 Major Machines
Jaw, Cone, Screen, Conveyors
Overcoming Operational Challenges
The client was facing multiple operational bottlenecks that were impacting productivity, increasing downtime and affecting the overall profitability of the plant.
Low Productivity
Existing plant configuration was unable to achieve desired output, leading to low production rates.
High Downtime
Frequent breakdowns and inefficient equipment resulted in unplanned downtime and revenue loss.
Material Blockage
High moisture content and improper material flow caused blockages and frequent stoppages.
Inconsistent Output
Irregular product gradation and low-quality output affected downstream operations.
Scaling & Future Readiness
The existing setup lacked scalability to meet future production demands.
LIMITING TOTAL POTENTIAL
These challenges were limiting the plant's true potential and impacting overall operational efficiency. Pithal was engaged to deliver a complete end-to-end solution to overcome these issues and ensure maximum performance.
Pithal Engineering Solution
Pithal delivered a customized, high-performance crushing & screening solution engineered for maximum efficiency, consistency and long-term operational reliability.
Strategic Machine Selection
Selected high-efficiency crushers, screens and conveyors to handle zinc ore with optimal crushing and throughput.
Optimized Workflow Design
Engineered a smooth material flow with ideal crushing, screening and conveying sequence to eliminate bottlenecks.
Advanced Engineering Strategy
Applied proven engineering principles and innovative designs to ensure durability, safety and performance.
Performance Optimization Logic
Fine-tuned equipment settings and system parameters to maximize output while minimizing energy consumption.
Intelligent Plant Layout Planning
Designed a compact, future-ready plant layout for efficient operations, easy maintenance and scalability.
Integrated & Optimized Plant Flow
Reliability
Engineered for continuous operation with minimal downtime.
Efficiency
Higher throughput with optimized power consumption.
Consistency
Uniform output quality for improved process performance.
Scalability
Future-ready design to support capacity expansion.
Our engineering team combined deep domain expertise with advanced design tools and real-world experience to deliver a solution that exceeds operational expectations and drives long-term value.
ENGINEERED FLOW. OPTIMIZED PERFORMANCE.
Our integrated crushing & screening solution is designed to ensure smooth material flow, maximum efficiency and consistent output quality.
RAW MATERIAL
Run-of-mine material dumped into hopper
PRIMARY CRUSHER
Jaw crusher reduces material size
SECONDARY CRUSHER
Cone crusher further reduces material
SCREENING
Vibrating screens separate material by size
PRIME CONVEYOR SYSTEM
Efficient conveying ensures continuous flow
FINAL OUTPUT
High-quality, uniform material ready for use
OPTIMIZED FLOW
Smooth material flow at every stage
HIGHER EFFICIENCY
Maximized throughput with minimal downtime
CONSISTENT QUALITY
Uniform output with precise screening
LOWER OPERATING COST
Reduced wear, energy & maintenance
ADVANCED MACHINES. SUPERIOR PERFORMANCE.
High-efficiency equipment selected and configured to deliver maximum productivity, reliability and consistent output quality.
PRIME JAW CRUSHER
PEW 1100 x 750
Role In Plant:
Primary crushing of run-of-mine material into manageable size.
Key Specifications:
PRIME CONE CRUSHER
PCH 220
Role In Plant:
Secondary crushing for further size reduction and shape control.
Key Specifications:
PRIME VSI CRUSHER
PVSI 1145
Role In Plant:
Tertiary crushing & shaping for high-quality, cubical products.
Key Specifications:
PRIME VIBRATING SCREEN
3YK 2160
Role In Plant:
Separation and classification of material by size.
Key Specifications:
BELT CONVEYORS
BC Series
Role In Plant:
Efficient material transfer between different stages of the plant.
Key Specifications:
BUILT FOR DURABILITY. ENGINEERED FOR RESULTS.
All machines are selected for optimal performance, low maintenance and long service life in the toughest operating conditions.
High Efficiency
Maximized output with low energy consumption
Reliable Performance
Designed for continuous operation
Low Maintenance
Easy access design for quick inspection & servicing
Proven Technology
Globally trusted equipment with local support
BUILT ON PRECISION. EXECUTED TO PERFECTION.
From equipment handling to installation and commissioning, every step is executed with precision, safety and strict quality standards.
PLANT SETUP
Complete plant layout and equipment arrangement as per engineered design.
CRANE LIFTING
Safe and efficient lifting of heavy machinery using advanced cranes and rigging.
EQUIPMENT INSTALLATION
Precise installation and alignment of crushers, screens and conveyors.
FABRICATION
In-house fabrication of structural components ensuring strength and durability.
SITE ENGINEERS
Our expert team supervising on-site execution with strict adherence to safety and quality.
COMMISSIONING
Final testing, trial runs and commissioning for smooth and reliable plant operation.
MEASURABLE RESULTS. MAXIMUM IMPACT.
Our engineered solution delivered significant improvement in productivity, reliability and operational efficiency, ensuring consistent output and lower operating costs.
HIGHER PRODUCTIVITY
Increased throughput with optimized crushing & screening process.
LOWER DOWNTIME
Enhanced equipment reliability and reduced breakdowns.
MATERIAL CONSISTENCY
Uniform output quality with precise screening & reduction.
ENERGY OPTIMIZATION
Lower power consumption with efficient equipment integration.
CONTINUOUS OPERATION
Built for nonstop performance and maximum uptime.
PERFORMANCE COMPARISON
KEY OUTCOMES DELIVERED
ENGINEERED FOR PERFORMANCE.
PROVEN IN REAL-WORLD OPERATIONS.
“ The Pithal solution has transformed our operations with higher efficiency, consistent output and exceptional reliability. ”— Plant Head, Leading Mining Company
BUILT TO DELIVER.
DESIGNED TO PERFORM.
TRUSTED BY INDUSTRY LEADERS. PROVEN BY RESULTS.
Our commitment to engineering excellence and customer success has earned the trust of leading companies across industries.
“ Pithal delivered a reliable crushing solution tailored to our operational requirements with excellent support throughout installation and commissioning. ”
The team demonstrated deep engineering expertise, understood our challenges and delivered a plant that exceeded our productivity expectations.
Ravi Sharma
Plant Head | Leading Mining Company
PROUD TO PARTNER WITH INDUSTRY LEADERS
GLOBAL REACH. LOCAL SUPPORT. ALWAYS WITH YOU.
Pithal Engineering delivers world-class solutions backed by strong global capabilities and dedicated support at every stage of your plant's journey.
EXPORT READINESS
- Equipment designed to global quality standards
- Compliant with international safety & performance norms
- Exported to 35+ countries across 6 continents
- End-to-end documentation & logistics support
AFTER-SALES SUPPORT
- 24/7 dedicated support team
- Quick response & on-site assistance
- Genuine spare parts availability
- AMC & service contracts for worry-free operations
ENGINEERING ASSISTANCE
- Process optimization & plant performance review
- Upgradation & capacity enhancement support
- Custom solutions tailored to your needs
- Expert guidance from concept to commissioning
OPERATIONAL GUIDANCE
- Operational training for better efficiency
- Preventive maintenance guidance
- Troubleshooting & performance monitoring
- Continuous support for maximum uptime
From engineering excellence to lifetime support, we ensure your success at every step.
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Proven Expertise
Decades of experience in heavy engineering
Tailored Solutions
Custom-built for your operational needs
Maximum ROI
Optimized performance that delivers results
End-to-End Support
We partner with you at every stage
Engineering Consultation
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Project Planning
We plan every detail to ensure smooth execution and delivery.
Plant Optimization
Improve efficiency, reduce downtime and cut operating costs.
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