ZR100SF Stacker conveyor

The ZR100SF Stacker Conveyor is ZOOMRY's core equipment developed for large-capacity bulk material stockpiling scenarios. Equipped with a 1000mm-wide belt, it achieves a maximum handling capacity of 1000 tonnes per hour (tph) at a belt speed of 2.5m/s, with its stockpiling capacity increased by 28% compared to traditional models. Combined with a 12-25m telescopic boom, as well as radial rotation and luffing lifting functions, it can accurately control the entire stockpiling process of bulk materials such as coal and ore, fundamentally reducing dust and noise generation, as well as 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, EAC, and KCS, it is a reliable choice for scenarios such as large port berths and large-scale mining stockyards.

Core Functions of the ZR100SF Stacker Conveyor

Radial Rotation

The ZR100SF Stacker Conveyor is equipped with an upgraded hydraulically driven radial rotation system, enabling 360° full-range stockpiling. It maintains an industry-leading maximum steering angle of 110°, which is a 57% increase compared to the 70° operating range of ordinary belt conveyors. In large port bulk cargo berths or 10,000-tonne-class mining stockyards, material distribution across multiple areas can be completed without frequent equipment movement. Taking iron ore stockpiling in mining as an example, a single unit can cover an operating area with a diameter of 60 meters, reducing equipment investment by 40% compared to the traditional solution of combining multiple fixed stackers, while also lowering the complexity of coordinated scheduling between devices. This design not only improves site utilization but also avoids energy waste caused by frequent equipment start-ups and shutdowns.

Telescopic Adjustment

The telescopic boom adopts a high-strength alloy steel structure, with a standard adjustment range of 12-25 meters, and has been specially reinforced for large-capacity stockpiling scenarios. When extended to 25 meters, it can achieve continuous material spreading for "long strip-shaped material piles," with the bulk material processing capacity per stockpiling cycle increased by 35% compared to traditional equipment. When retracted to 12 meters, it can adapt to compact operations in small and medium-sized temporary stockyards, avoiding energy redundancy caused by "overcapacity" of the equipment. At the same time, the telescopic system is equipped with ZOOMRY's self-developed "mute-guided" cable sliding device. Different from traditional designs, its operating noise is below 65dB (15% lower than ordinary devices in the industry), and the cable wear rate is reduced by 40%, with a service life extended to over 8 years, reducing maintenance frequency in large-capacity operation scenarios.

Luffing Lifting

The luffing mechanism is driven by the linkage of three hydraulic cylinders, with a maximum stockpiling height of 22 meters. Combined with the "graded falling" control logic, it can accurately adapt to stockpiling methods according to material characteristics. When handling dust-prone materials such as coal, the falling height can be controlled within 1.2 meters, with dust concentration below 35mg/m³, complying with EU industrial environmental standards. When handling heavy bulk materials such as iron ore, luffing adjustment enables uniform material spreading, avoiding compaction and agglomeration caused by excessive local accumulation (compaction rate controlled below 2%). In addition, the operating noise of the luffing system is below 70dB, 20% lower than traditional hydraulic luffing equipment, effectively improving the noise environment at large-scale operation sites and reducing impact on the surrounding environment.

It is worth noting that the core reason for the 28% increase in stockpiling capacity of the ZR100SF Stacker Conveyor compared to traditional models lies in the coordinated optimization of the three major functions: radial rotation expands the coverage range, telescopic adjustment extends the material spreading length, and luffing lifting improves vertical space utilization. The combination of these three functions increases the stockpiling density per unit area, making it particularly suitable for port and mining scenarios with "high land costs and large operation scales," and significantly improving the production capacity per unit site compared to traditional equipment.

Core Components

Drive and Hydraulic System

The drive system can optionally adopt first-tier international brand gear motors such as SEW (Germany) and FLENDER (Germany), with output power upgraded to 45kW (main conveyor) + 20kW (chassis), which can stably support the continuous conveying needs of large-capacity bulk materials. The motor efficiency reaches over 96.5%, saving 13% more energy than ordinary motors. Calculated based on 300 working days per year, it can save approximately 18,000 yuan in electricity costs. The hydraulic power pack adopts a custom system developed by ZOOMRY, with an oil tank capacity expanded to 700 liters and equipped with a triple filtration device (higher than the industry's dual filtration standard). The hydraulic oil cleanliness reaches NAS Class 7, reducing the wear rate of hydraulic components by 50%, and the annual system failure rate is below 0.3%. This is crucial for large-capacity operations, as it can avoid large-scale production shutdowns caused by equipment failures. Based on a handling capacity of 800tph, each hour of reduced downtime can avoid delays in processing 800 tonnes of materials.

Control System

The equipment supports two core modes: PLC fully automatic control and remote control, paired with a 10-inch high-definition HMI touchscreen (supporting multi-language switching including English, Russian, and Korean). The operation interface is optimized for large-capacity operations:

1. PLC Fully Automatic Mode: It can preset large-scale stockpiling paths such as "stepped stockpiling" and "circular stockpiling." The system automatically adjusts the radial rotation speed, telescopic boom length, and luffing height according to the incoming material volume, without manual intervention. A single unit can replace 4-5 operators, significantly reducing labor costs. At the same time, it supports multi-equipment coordinated control, and 2-3 ZR100SF Stacker Conveyors can be operated in linkage through the central control system to meet the stockpiling needs after 10,000-tonne-class bulk cargo unloading at ports.
2. Remote Control Mode: Equipped with an enhanced wireless remote control, the operating distance is increased to 80 meters, and anti-interference capability is strengthened. Stable operation is ensured even in harsh electromagnetic environments at ports or dusty environments in mining areas. Operators can observe the material stockpiling status in a safe area and adjust parameters in real time, avoiding health risks caused by close contact with high-dust and high-noise environments.

In emergency situations, the equipment can quickly switch to manual operation mode to ensure controllability under unexpected circumstances. The three modes are seamlessly connected, perfectly adapting to the needs of "continuous large-scale operation + flexible fine-tuning" in large-capacity operations.

Safety and Cleaning Systems

In terms of safety design, considering the characteristics of "heavy material weight and high risk coefficient" in large-capacity operations, the ZR100SF Stacker Conveyor has been strengthened in multiple aspects: In case of power failure, the hydraulic system automatically locks within 0.008 seconds (faster than the industry standard of 0.01 seconds), preventing the telescopic boom from suddenly falling due to bearing heavy materials; the steel wire rope is equipped with dual mechanical limit + tension detection devices. Once breakage or abnormal tension occurs, the telescopic boom is immediately locked and an audible-visual alarm is triggered; high-precision deviation switches are installed on both sides of the belt. When the deviation exceeds ±25mm, the equipment automatically shuts down, avoiding large-capacity material spillage caused by belt deviation (single spillage loss can be controlled within 50kg).

The cleaning and maintenance design focuses on "easy operation and low cost": The head and tail of the equipment are each equipped with two sets of high-strength polyurethane (PU) cleaning scrapers, totaling 8 sets (for 3-phase power supply configuration), with a cleaning rate of 99.2%, which can completely remove residual bulk material debris on the belt surface and reduce belt wear; the scrapers adopt a "quick-release" design, requiring only 20 minutes for individual replacement, which is 67% shorter than the industry average maintenance time of 1 hour. In addition, key components of the equipment (such as hydraulic filters and idlers) are designed with uniform specifications, and convenient maintenance ports are reserved. Engineers can complete replacement without disassembling complex structures, further reducing maintenance difficulty and costs.

Convenient Transportation and Efficient Installation

For global large-capacity bulk material projects, the difficulty of cross-border transportation of equipment and on-site installation cycle directly affect the project's production launch progress. The "modular pre-assembly + high-adaptability transportation" design of the ZR100SF specifically addresses the pain points of "difficult transportation and long installation time" of large-capacity equipment, ensuring the project is quickly implemented and generates revenue as soon as possible.

40-Foot High Cube (HQ) Container Transportation

Despite being a large-capacity stockpiling equipment, the ZR100SF Stacker Conveyor still achieves 40-foot HQ container adaptability for its core components through lightweight optimization and modular disassembly. The entire machine is disassembled into 6 standard units, including the telescopic boom module, chassis module, and hydraulic power pack module. Each unit's size complies with the transportation limits of a 40-foot HQ container (length 12.03m × width 2.35m × height 2.69m), eliminating the need to apply for over-width or over-height transportation permits. Compared to the "bulk + special transportation" solution for traditional large-capacity equipment, cross-border logistics costs are reduced by 35%, 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, 90% of the equipment's pre-assembly work is completed, which is a 12.5% improvement compared to the industry's 80% pre-assembly standard. Hydraulic pipelines, electrical circuits, and core component connections have all undergone 150-hour full-load testing to ensure trouble-free on-site installation. On-site, only 3 key processes need to be completed: docking of the telescopic boom and chassis, venting of the hydraulic system, and connection of electrical plugs. ZOOMRY provides a guidance manual with step-by-step operation instructions; if customers require, senior engineers can be dispatched to supervise on-site installation and conduct operator training simultaneously. 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 50% shorter than the average 40-day installation cycle of large-capacity stockpiling equipment in the industry.

Adapting to Multi-Market Standards

The equipment has obtained the EU CE certification (Machinery Directive 2006/42/EC and Electromagnetic Compatibility Directive 2014/30/EU), meeting the safety and environmental requirements for large-capacity machinery in the European Economic Area (EEA); it has passed the EAC certification of the Eurasian Customs Union, covering the cold and dusty operating environments of CIS countries; and has also obtained the South Korean KCS certification, adapting to the strict standards for equipment noise and dust emissions at South Korean ports. In addition, the equipment fully complies with the ISO 9001 Quality Management System and ISO 14001 Environmental Management System, with full traceability throughout the production process. From material testing of high-strength steel to tightness testing of the hydraulic system, each process has detailed quality records to ensure consistency in mass production.

The quality control of core components is aligned with high international standards: The idlers adopt ZOOMRY's self-developed high-wear-resistant model, with radial runout ≤ 0.4mm (better than the 0.5mm of China's GB standard) and rotational resistance ≤ 2N (better than the ≤ 3N of GB standard), with a service life exceeding 50,000 hours; the roller shaft uses 40Cr forged parts (diameter ≥ 220mm, adapting to large-capacity conveying needs), and the shell undergoes CNC four-roll rounding processing with ovality < 1.5mm. After welding, it undergoes ultrasonic flaw detection and tempering treatment to eliminate internal stress, ensuring no deformation under long-term heavy material bearing. ZOOMRY's self-built quality testing center (including chemical laboratories, hardness laboratories, hydraulic system testing laboratories, etc.) is equipped with more than 60 professional devices. Each ZR100SF Stacker Conveyor must pass 15 strict tests before leaving the factory, such as load testing, noise testing, and dust control testing, to ensure performance compliance.

Application Scenarios

In the scenario of large port berths, the equipment is mainly used for large-scale stockpiling of bulk materials such as coal, iron ore, and grain after ship unloading. For large berths capable of accommodating Panamax ships (60,000-80,000 DWT), its large-capacity stockpiling capacity can match the high unloading efficiency of ship unloaders (e.g., 1000 tonnes per hour unloading volume), avoiding ship unloader waiting due to slow stockpiling. The 12-25m telescopic boom length and 360° radial rotation can flexibly utilize the large stockpiling area behind the berth, with stockpiling capacity increased by 28% compared to traditional equipment, reducing the cost of temporary bulk material transfer. At the same time, the low-dust design complies with the environmental requirements of international ports, eliminating the need for additional dust removal equipment and reducing initial project investment.

In the scenario of large-scale mining stockyards, the equipment can handle heavy bulk materials such as iron ore, limestone, and coal, adapting to the operation rhythm of "10,000-tonne-class mining and large-scale stockpiling." If the stockyard has complex terrain, an optional reinforced tracked tail (ground pressure of 0.07MPa) can be installed, with a climbing capacity of 20°, enabling flexible movement even on muddy and rough mining ground. The 22m stockpiling height design can maximize the use of vertical space in the stockyard, reducing the site occupation area by 50% compared to traditional 10m stockpiling equipment. Based on annual stockpiling of 1 million tonnes of bulk materials, it can save approximately 300,000 yuan in site rental costs. By controlling the material falling height through luffing lifting, it can also reduce the degradation of high-hardness ore (e.g., limestone degradation rate reduced from 5% of traditional stockpiling to below 0.8%), reducing the processing pressure for subsequent crushing and grinding processes and improving overall production efficiency.

Technical Parameters

Choosing ZOOMRY

Cost Reduction and Efficiency Improvement in Large-Scale Operations

By choosing the ZR100SF Stacker Conveyor, customers can obtain significant value from three dimensions: equipment investment, operating costs, and revenue cycle. At the equipment level, the 28% stockpiling capacity advantage can reduce equipment investment by 40%—for example, only 2 units are needed for large port berths to replace 3 traditional fixed stackers. At the operating level, automatic control replaces 4-5 operators, resulting in annual labor cost savings of approximately 200,000 yuan; the low-failure design controls annual downtime within 30 hours, reducing downtime losses by 50% compared to the industry average of 60 hours; meanwhile, the low-dust and low-noise characteristics avoid environmental fines. At the revenue level, fast installation and production launch in 10-20 days shorten the cycle by 50% compared to the industry average of 40 days, enabling early revenue generation.

Service Support

In response to the service needs of global large-capacity projects, ZOOMRY has established a comprehensive support system covering "technology, on-site service, and spare parts": It provides multi-language technical documents (including operation manuals, maintenance guides, and troubleshooting manuals), 24/7 online technical consultation, with an engineer response time of no more than 3 hours; for key projects, engineers with over 10 years of experience in large-capacity equipment can be dispatched to the site to provide installation guidance, equipment commissioning, and special operator training (5-day training duration to ensure the team masters operation skills for large-scale operations); there is sufficient inventory of common spare parts (such as PU scrapers, hydraulic filters, and idlers), with a delivery cycle of no more than 4 days, significantly shortening maintenance waiting time and ensuring long-term stable operation of large-scale projects.