ZR90SF Stacker conveyor

The ZR90SF Stacker Conveyor is ZOOMRY's main model focusing on medium-scale bulk material stockpiling. Equipped with a 914mm-wide belt, it achieves a stable handling capacity of 700 tph at a belt speed of 2.5 m/s. Combined with an adjustable telescopic boom of 10-20 m, plus radial rotation and luffing lifting functions, it can accurately control the entire stockpiling process of bulk materials such as coal and ore, fundamentally avoiding issues of material segregation, degradation, contamination, and compaction. It supports transportation via 40-foot high cube (HQ) containers, and on-site installation can be completed within 10-20 days after pre-assembly. With international certifications including CE and EAC, it is a preferred stockpiling equipment for scenarios such as medium-sized port berths and large-scale mining stockyards.

Core Functions of the ZR90SF Stacker Conveyor

As a professional radial luffing stacking equipment, the core competitiveness of the ZR90SF Stacker Conveyor lies in its targeted solution to the pain points of medium-scale bulk material stockpiling. Through the synergistic operation of three core functions—"radial rotation, telescopic adjustment, and luffing lifting"—it not only solves the problems of "low stockpiling efficiency and high material loss" of traditional equipment but also meets the dual demands of "flexibility and stability" for medium-scale operation scenarios.

Radial Rotation

The equipment is equipped with a hydraulically driven radial rotation system, enabling 360° dead-angle-free stockpiling operations with a maximum steering angle of 110°, which is a 57% increase compared to the 70° operating range of ordinary belt conveyors. In medium-sized port berths or large-scale mining stockyards, there is no need to frequently move the main body of the equipment; material distribution across multiple areas can be completed solely through radial rotation. Taking port coal stockpiling as an example, a single unit can cover an operating area with a diameter of 50 meters, reducing displacement time by 50% compared to traditional fixed stackers. It is particularly suitable for the operational needs of medium-scale sites that "require wide coverage while saving space". It not only improves site utilization but also avoids energy waste caused by frequent equipment start-ups and shutdowns, saving approximately 1.5 kWh of electricity per hour.

Telescopic Adjustment

The telescopic boom adopts a high-strength lightweight steel structure (instead of the traditional lattice frame), with a standard adjustment range of 10-20 m, which can be flexibly adjusted according to the material volume. When handling small batches of bulk materials, shortening the boom to 10 m can reduce the idle length of the belt and lower unnecessary energy consumption by 20%. When facing large-scale continuous stockpiling, extending the boom to 20 m can prevent compaction and agglomeration caused by overly dense material accumulation (e.g., ore compaction rate can be controlled below 3%). At the same time, the telescopic system is equipped with ZOOMRY's self-developed "linear guidance" cable sliding device. Different from the traditional "curtain-type" design, the cable sliding resistance is reduced by 30%, eliminating jamming and wear issues. Its service life is increased by 60% compared to ordinary devices in the industry, reducing maintenance frequency in medium-scale operation scenarios.

Luffing Lifting

The luffing mechanism is driven by dual hydraulic cylinders (instead of a single cable system), with a maximum stockpiling height of 20 m, and can automatically adapt the falling height according to the angle of repose of different materials. When stockpiling iron ore (with an angle of repose of 38°), the falling height can be accurately controlled to 1.2 m, keeping the material impact degradation rate within 1%. When stockpiling coal (with an angle of repose of 35°), the falling height is adjusted to 1.5 m, effectively reducing dust emission (dust concentration below 40 mg/m³), meeting port environmental protection requirements, ensuring stable material quality, and maximizing the use of vertical space. Compared with traditional equipment with a 6-8 m stockpiling height, its stockpiling capacity is increased by 150%, making it especially suitable for the operational needs of medium-scale sites to "increase capacity in limited space".

In addition, through layered stockpiling, material segregation is avoided (the uniform distribution error of materials with different particle sizes is ≤5%); controlling the falling height reduces degradation; sealed stockpiling isolates external contamination (e.g., rainwater and impurity mixing rate is below 0.5%); and dispersed material distribution reduces bottom-layer compaction (the difference in compaction density between bottom and upper materials is ≤8%). It is particularly suitable for scenarios with high stockpiling quality requirements, such as port bulk materials and heavy mining raw materials.

Core Components of the ZR90SF Stacker Conveyor

Drive and Hydraulic System

The drive system can optionally adopt internationally renowned brand gear motors such as SEW (Germany) and FLENDER (Germany), with an output power of 37 kW (main conveyor) + 15 kW (chassis), accurately adapting to the 700 tph handling requirement. The motor efficiency reaches over 96%, saving 12% more energy than ordinary motors, with annual electricity savings of up to 18,000 kWh. The hydraulic power pack adopts a top-tier Chinese hydraulic system, with an oil tank capacity of 600-650 liters and a triple filtration system (instead of dual filtration). The hydraulic oil cleanliness reaches NAS Class 7 (surpassing the industry's NAS Class 8 standard), reducing the wear rate of hydraulic components by 40%, and the annual system failure rate is less than 0.3%, far lower than the industry average of 1.2%.

Control System

The equipment supports two core modes: PLC fully automatic control and remote control, paired with a 7-inch HMI touchscreen (supporting multi-language switching including English, Russian, and Spanish). The operation interface is simple and intuitive, allowing customers from different regions to get started quickly:

1. PLC Fully Automatic Mode: Preset paths such as "linear stacking" and "fan-shaped stacking" through a programmable controller. The equipment automatically adjusts the radial rotation angle, telescopic boom length, and luffing height without manual intervention. A single unit can replace 3-4 operators, reducing labor costs. Meanwhile, the system can collect stacking data in real-time (e.g., material volume, stockpiling height) and generate operation reports for convenient customer management.
2. Remote Control Mode: Equipped with a wireless remote control (with an operating range of up to 60 meters, exceeding the industry's 50-meter standard), operators can observe the material stockpiling status in a safe area and adjust parameters in real-time. In response to sudden bulk material fluctuations after port unloading, it can quickly adjust to avoid material overflow or uneven stockpiling.

In emergency situations, it can be switched to manual operation mode to ensure equipment controllability. The three modes switch seamlessly, adapting to the dual needs of "continuous large-scale stockpiling" and "emergency fine adjustment" in medium-scale operations.

Safety System

Considering the characteristics of "fewer personnel and high operation intensity" in medium-scale operations, the safety system of the ZR90SF Stacker Conveyor fully covers risk scenarios such as "power failure, cable breakage, and belt deviation". In case of power failure, the hydraulic system automatically locks within 0.008 seconds (faster than the industry's 0.01-second standard) to prevent the telescopic boom from suddenly falling. When the steel cable breaks, the dual mechanical limit devices immediately lock the telescopic boom and trigger an audible and visual alarm to remind on-site personnel to evacuate. High-precision tilt switches are installed on both sides of the belt; when the deviation exceeds ±30 mm, the equipment automatically shuts down to prevent belt wear (extending the belt service life to over 3 years) or material spillage. The entire safety design complies with the EU Machinery Safety Directive (2006/42/EC), providing solid protection for operational safety.

Cleaning and Maintenance Components

The head and tail of the equipment are each equipped with a set of high-strength polyurethane (PU) cleaning scrapers, totaling 4 sets (for 3-phase power supply configuration), with a cleaning rate of 99% (higher than the industry's 98% standard). They can completely remove residual materials on the belt surface (e.g., ore powder, coal debris) and reduce belt wear. The scrapers adopt a modular design, requiring only 30 minutes for individual replacement (faster than the industry's 1-hour standard) with low maintenance costs. For the ultra-heavy stockpiling needs of large-scale mining stockyards, bilateral maintenance walkways can be added (with a load-bearing capacity of 250 kg/㎡, higher than the industry's 200 kg/㎡ standard), making it safer and more convenient for engineers to inspect and maintain, meeting the "low maintenance and high efficiency" needs of medium-scale operations.

Convenient Transportation and Efficient Installation

40-Foot High Cube (HQ) Container Transportation

The main structure of the equipment has undergone lightweight optimization. All core components (telescopic boom, hydraulic power pack, control system) can be disassembled into standard modules suitable for 40-foot HQ containers, eliminating the need to apply for over-width or over-height transportation permits. Compared with traditional bulk transportation, cross-border logistics costs are reduced by 30%, and it can be transported by regular container ships, avoiding cycle delays caused by special logistics.

On-Site Installation in 10-20 Days

Before leaving the factory, the equipment has completed 85% of pre-assembly work (higher than the industry's 80% standard). Key parts such as hydraulic pipelines and electrical circuits have undergone 100-hour full-load testing to ensure trouble-free on-site installation. On-site, only simple processes are required, such as telescopic boom docking, hydraulic system venting, and electrical plug connection. ZOOMRY provides a guidance manual, and if customers have needs, engineers can be dispatched to supervise the installation on-site. According to historical project data, a skilled team can complete installation and commissioning in as fast as 10 days, and no more than 20 days at the slowest, which is 1/3 shorter than the industry's average cycle of 30 days.

Adapting to Multi-Market Standards

The ZR90SF Stacker Conveyor complies with the EU CE certification (Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive 2014/30/EU) and can directly enter the European Economic Area (EEA) market. It has passed the EAC certification of the Eurasian Customs Union, covering CIS countries such as Russia, Kazakhstan, and Belarus, meeting local safety and environmental protection requirements for heavy industrial equipment. At the same time, it fully adheres to the ISO 9001 Quality Management System and ISO 14001 Environmental Management System, with full traceability throughout the production process. From the incoming inspection of raw materials (e.g., material testing of high-strength steel) to the delivery of finished products, each process has quality records to ensure stable equipment quality.

Core components (such as idlers and rollers) have all passed the testing of CEMA (Conveyor Equipment Manufacturers Association, USA) standards: idler radial runout ≤ 0.4 mm, rotational resistance ≤ 2 N, and service life exceeding 50,000 hours; the roller shaft adopts 40Cr forged parts (diameter ≥ 200 mm), the shell undergoes CNC four-roll rounding processing (ellipticity < 1.5 mm), and after welding, it undergoes ultrasonic flaw detection and tempering treatment to eliminate internal stress, with a service life also exceeding 50,000 hours. ZOOMRY has built its own quality testing center (including chemical laboratories, hardness laboratories, hydraulic system testing laboratories, etc.), equipped with more than 60 professional testing devices. Each ZR90SF Stacker Conveyor must undergo 12 rigorous tests before leaving the factory, such as load testing, noise testing, and hydraulic tightness testing, to ensure performance compliance. This strict quality control ensures that the equipment can operate stably under different working conditions around the world.

Application Scenarios

In the scenario of medium-sized port berths, the equipment is mainly used for stockpiling bulk materials such as coal, iron ore, and grain after ship unloading. For the unloading efficiency of medium-sized berths (capable of accommodating Handysize vessels of 10,000-35,000 DWT), the 700 tph handling capacity can perfectly match the operation rhythm of ship unloaders, avoiding waiting time for ship unloaders due to slow stockpiling. Meanwhile, the 10-20 m telescopic boom length and 360° radial rotation can flexibly utilize the limited space of the berth, maximizing stockpiling capacity (increased by 40% compared to traditional fixed stackers). Combined with the sealed stockpiling design, it reduces dust emission, meeting the environmental protection requirements of ports in Europe, Southeast Asia, and other regions (e.g., EU dust emission limit ≤ 50 mg/m³).

In the scenario of large-scale mining stockyards, the equipment can handle heavy bulk materials such as iron ore, limestone, and coal (with a maximum material particle size of up to 400 mm) and adapt to complex terrains. If the stockyard terrain is muddy or rough, an optional tracked tail (with a ground pressure of 0.08 MPa) can be installed, and the equipment's climbing capacity reaches 18° (higher than the industry's 15° standard) to avoid getting stuck. The 20 m stockpiling height design can maximize the use of the vertical space of the stockyard, reducing the site rental area (site utilization increased by 150% compared to equipment with 6-8 m stockpiling height). By controlling the material falling height through luffing lifting, it can also reduce the degradation of high-hardness ore (e.g., the degradation rate of iron ore is reduced from 5% of traditional stockpiling to less than 1%), reducing the processing pressure for subsequent crushing and grinding processes and improving overall production efficiency.

Technical Parameters

Choosing ZOOMRY

Multi-Dimensional Improvements in Cost Reduction and Efficiency Enhancement

By choosing the ZR90SF Stacker Conveyor, customers can obtain multi-dimensional value based on the core needs of medium-scale operations. In terms of cost control, automatic stockpiling replaces 3-4 operators, resulting in annual labor cost savings; the 700 tph handling capacity can match the efficiency of ship unloaders/conveyors, reducing dump truck transportation; the 20 m stockpiling height increases stockpiling capacity, reducing site rental or expansion costs. In terms of efficiency improvement, fast installation and commissioning in 10-20 days shortens the cycle by 1/3 compared to the industry average, generating revenue in advance; the annual equipment failure rate is less than 0.3%, and the Mean Time Between Failures (MTBF) reaches over 9,000 hours, reducing downtime losses; sealed stockpiling reduces dust emission, avoiding environmental fines, while the material utilization rate is increased to over 99.8%, reducing material loss.

Service Support

ZOOMRY deeply understands the service needs of global medium-scale projects and has established a comprehensive service system. It provides multi-language technical manuals (including operation, maintenance, and troubleshooting), 24/7 online technical consultation, with an engineer response time of no more than 3 hours (faster than the industry's 4-hour standard). For key projects, engineers can be dispatched to the site for installation guidance, equipment commissioning, and operator training (training duration: 3-5 days, ensuring the team masters operational skills proficiently). There is sufficient inventory of common spare parts, with a delivery cycle of no more than 5 days, reducing maintenance waiting time. This comprehensive "technology + on-site + spare parts" service ensures the long-term stable operation of the equipment and provides strong support for customers' medium-scale operations.