| Product name | Telescopic Stacker |
| Material | High Quality Carbon Steel |
| Belt width | 800mm - 1600mm; Customer |
| Max Capacity | 450-3500m³/h(Customer |
| Certification | ISO9001; CE; ISO14001; EAC; KCS |
| Advantages | Portable, rotatable, inclination adjustable, conveying length retractable, radial movement |
| Application | Mining, Port, Cement, Steel, Metallurgy, Electric Power, Coal, Machinery and Other Industries. |
The ZR160SF Stacker Conveyor is ZOOMRY's flagship model designed exclusively for ultra-large-scale heavy bulk material stockpiling in the global mining industry. Equipped with a 1600mm ultra-wide belt, it achieves an extreme throughput of 3500 tonnes per hour (tph) at a high speed of 4.0m/s. Based on an ultra-large load-resistant structural design, combined with a 10-20m telescopic boom and a 20m stockpiling height function, it can stably meet the large-scale stockpiling needs of heavy bulk materials such as iron ore and large coal lumps, significantly increasing the capacity of mining yards. The equipment supports PLC fully automatic stockpiling, completes 85% pre-assembly before leaving the factory, can be put into operation within 10-20 days on-site, and has obtained CE and EAC international certifications. It operates with low noise and low failure rates, making it the core ultra-large-scale stockpiling equipment for mining scenarios such as large open-pit mines and large-scale concentrators.
As a professional ultra-large-scale stockpiling equipment and radial telescopic stacker, the core competitiveness of the ZR160SF Stacker Conveyor lies in the three-fold advantages of "ultra-high-speed throughput + ultra-large stockpiling capacity + mining scenario adaptation". Addressing the pain points of the mining industry—"daily mining output reaching tens of thousands of tonnes, large yard areas, and complex characteristics of heavy bulk materials"—through ultra-large-scale optimization of functions and structures, it completely solves the problems of traditional stockpiling equipment such as "insufficient throughput, inadequate capacity, and poor weather resistance", perfectly matching the large-scale, high-intensity operation needs of mining stackers.
The equipment is equipped with a radial rotation system with triple hydraulic motor linkage. Based on an ultra-large chassis structural design, it enables 360° dead-angle-free stockpiling, maintains a maximum steering angle limit of 110°, and the stability of the machine body during rotation is 50% higher than that of ordinary large-scale stackers. In the large-scale yard of a large open-pit mine, a single ZR160SF Stacker Conveyor can cover an operating area with a diameter of 70 meters. This reduces equipment investment by 65% compared to the traditional combined solution of "4 medium-sized stackers + 3 transfer machines", while avoiding the complex process of multi-equipment coordinated scheduling. This design not only reduces the initial equipment procurement cost of the mining industry (saving approximately 6 million yuan based on the average price of a single unit) but also reduces the connection loss between equipment, increasing the stockpiling efficiency by 30% compared to traditional solutions, fully adapting to the "large yard, high continuity" stockpiling needs of the mining industry.
The telescopic boom is integrally welded with Q690 high-strength alloy steel, and 20mm-thick reinforcing plates are added to key stress-bearing parts. The standard telescopic range is 10-20m, with special reinforcement for the characteristics of the mining industry—"large impact of heavy bulk materials and high dust concentration". When extended to 20m, it can realize continuous material spreading of "long strip-shaped high-density material piles", with an hourly stockpiling volume of 7000m³ (calculated based on the bulk density of iron ore of 2.5t/m³), 50% higher than that of medium-sized stackers of the same class. When retracted to 10m, it can meet the temporary emergency stockpiling needs of the mining industry, reducing the energy consumption of empty belt operation (saving approximately 3 kWh of electricity per hour). At the same time, the telescopic system is equipped with a "heavy-duty dust-proof and torsion-resistant" cable sliding device independently developed by ZOOMRY, which adopts a three-layer sealed structure and alloy guide rails. It can resist the high-dust and strong-vibration environment of mining yards, reducing cable wear by 70% and extending the service life to more than 12 years, significantly reducing the maintenance frequency and cost of ultra-large-scale equipment.
The luffing mechanism adopts a six-hydraulic cylinder synchronous drive design, with a maximum stockpiling height of 20 meters—twice that of traditional mining stackers (8-10m)—which can maximize the use of the vertical space of mining yards. Calculated based on a single 10,000㎡ mining stockpiling area, the stockpiling capacity of the ZR160SF Stacker Conveyor can reach 300,000 cubic meters (approximately 750,000 tonnes of iron ore), increasing the yard utilization rate by 100% compared to traditional stackers, which is equivalent to saving 5,000㎡ of land occupation for mining enterprises. In addition, aiming at the characteristic of mining heavy bulk materials—"large single-piece weight (up to 100kg)"—the luffing system is equipped with a "multi-stage buffer material dropping" control logic, which can accurately control the material dropping height within 0.8m, reducing the impact on the belt and machine body. The service life of the belt is 80% longer than that of ordinary large-scale stackers, perfectly adapting to the high-intensity stockpiling needs of the mining industry.
The ZR160SF Stacker Conveyor can stably handle the ultra-high-speed throughput of 3500tph, mainly due to the targeted design of core components around "ultra-large-scale, high load, and mining weather resistance". From the drive system to safety protection, each component has undergone ultra-large-scale mining working condition simulation tests in ZOOMRY's Quality Testing Center, ensuring low noise and low failure rates in the continuous high-load, high-dust, and strong-vibration environment of the mining industry.
The drive system selects ultra-large gear motors from international first-tier brands such as SEW (Germany) and FLENDER (Germany), with output power upgraded to 90kW (main conveyor) + 30kW (chassis). The motor rotor adopts an ultra-high silicon steel sheet lamination process, with a rated torque of 4500N·m, which can stably support the ultra-high-speed continuous conveying needs of 3500tph heavy bulk materials. The motor efficiency reaches over 98%, saving 15% more energy than ordinary large-scale motors. The hydraulic power pack adopts a customized ultra-large system by ZOOMRY, with an oil tank capacity expanded to 800L, equipped with a four-stage high-precision filtration device (filtration accuracy of 5μm). The hydraulic oil cleanliness is maintained at NAS Class 6 (better than the industry NAS Class 7 standard), reducing the wear rate of hydraulic components by 60%, and the annual system failure rate is less than 0.1%.
The equipment is centered on PLC fully automatic stockpiling, paired with a 15-inch high-definition HMI touchscreen (supporting multi-language switching including English, Russian, and Spanish). The interface is deeply optimized for the mining industry's needs of "large-scale and low labor input":
In terms of safety design, aiming at the characteristics of mining ultra-large-scale stockpiling—"strong impact of heavy bulk materials and wide impact of accidents"—the ZR160SF Stacker Conveyor has been strengthened in four aspects: In case of power failure, the hydraulic system automatically locks within 0.004 seconds. The locking mechanism is made of 42CrMo forged material, which can withstand an instantaneous impact force of 120 tonnes, preventing the telescopic boom from suddenly falling due to carrying ultra-heavy bulk materials; the steel wire rope is equipped with a triple mechanical limit + real-time tension monitoring system. If the tension deviation exceeds 3%, it triggers locking immediately and cuts off the main drive power at the same time to avoid the risk of rope breakage; ultra-large anti-deviation switches are installed on both sides of the belt, using a cast steel housing and double-spring trigger structure. When the deviation exceeds ±40mm, it automatically shuts down and links the front-end conveyor to stop, preventing continuous spilling of heavy bulk materials (the loss of a single spill can be controlled within 200kg); impact-resistant buffer devices are added to key parts of the machine body, which can resist accidental impact of large materials (single piece over 100kg) and protect the ultra-large structure from damage.
The cleaning system adopts a combined design of "heavy-duty scrapers + high-pressure spray": The head and tail are each equipped with two sets of ultra-wear-resistant polyurethane (PU) scrapers (30mm thick), and the scraper surface is coated with tungsten carbide, with a cleaning rate of 99.8%, which can completely remove the residual heavy bulk material debris (such as iron ore powder and coal lumps) on the belt surface; a high-pressure spray device (optional) is added inside the belt, which can clean the dust attached to the inner side of the belt in conjunction with the mining dust filter system, reducing idler wear. Both the scrapers and the spray device adopt a "quick-release flange" design, and individual replacement only takes 40 minutes, which is 30% shorter than the maintenance time of ordinary ultra-large-scale stackers, adapting to the mining industry's needs of "short shutdown time and high maintenance efficiency".
To address the pain points of global mining projects—"difficult cross-border equipment transportation and long installation cycles"—the ZR160SF adopts an "ultra-large modular disassembly + high-proportion pre-assembly" design, which significantly reduces transportation and installation difficulties while ensuring the strength of the ultra-large structure, ensuring the rapid commissioning of mining projects.
Despite being an ultra-large-scale stockpiling equipment, the ZR160SF Stacker Conveyor still decomposes its core components into 5 standard units—"ultra-large chassis module (2 segments), segmented telescopic boom module (3 segments), hydraulic power pack module, and drive module"—through scientific modular disassembly. Among them, the ultra-large chassis module adopts lightweight high-strength steel, with single-segment weight controlled within 30 tonnes; each segment of the telescopic boom module is 10m long, with single-segment weight not exceeding 18 tonnes. All unit sizes are compatible with 40-foot HQ containers (12.03m in length × 2.35m in width × 2.69m in height), without the need to apply for over-width, over-weight, or over-height transportation permits. Compared to the traditional "bulk + special transportation" solution for ultra-large-scale equipment, cross-border logistics costs are reduced by 50%, and it can be transported by regular container ships, avoiding cycle delays caused by special logistics.
Before leaving the factory, the equipment completes 85% of the pre-assembly work. Key processes such as ultra-large structural welding, high-pressure connection of hydraulic pipelines, and explosion-proof laying of electrical wires are all completed in the factory, and undergo 200-hour full-load ultra-large-scale testing (simulating the continuous conveying scenario of 3500tph heavy bulk materials) to ensure no failures during on-site installation. On-site, only 3 core processes need to be completed: "segmented docking of the telescopic boom (using high-strength bolt connection with a torque of 1200N·m), venting of the hydraulic system, and commissioning of the PLC control system". ZOOMRY provides an instruction manual including a list of special torque wrenches for ultra-large-scale equipment installation and 3D installation animations. If customers require, engineers with over 20 years of experience in mining ultra-large-scale equipment can be dispatched to supervise on-site installation and conduct special operator training (including explosion-proof operation and emergency handling) at the same time. According to historical project data, a skilled team can complete installation and commissioning in as fast as 12 days, and no more than 20 days at the slowest, which is 56% shorter than the industry average installation cycle of 45 days for ultra-large-scale stackers.
The equipment has obtained EU CE certification (Machinery Directive 2006/42/EC) and completed 15 special tests for the safety requirements of ultra-large-scale machinery (including ultra-large structural load-bearing strength, explosion-proof performance, and electrical safety protection), enabling it to directly enter the European Economic Area (EEA) mining market; it has passed the EAC certification of the Eurasian Customs Union, meeting the environmental requirements of "low temperature (below -35℃), heavy snow, and heavy bulk material operations" for the mining industry in CIS countries. All technical documents are provided in Russian to facilitate local regulatory review. 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 the material testing of ultra-large structural steel (yield strength ≥ 690MPa) to the ultra-high-pressure tightness test of the hydraulic system (withstanding 32MPa pressure without leakage), each process has detailed quality records to ensure consistency in mass production.
The quality control of core components is aligned with international ultra-large-scale mining equipment standards: The idlers adopt ultra-heavy-duty wear-resistant models independently developed by ZOOMRY, with the roller body made of 45# seamless steel pipe (15mm wall thickness), radial runout ≤ 0.3mm (better than China's GB standard of 0.5mm), rotational resistance ≤ 2.0N (better than the GB standard of ≤ 3N), and the bearings are ultra-heavy-duty self-aligning roller bearings (Model 22320) with a service life of over 50,000 hours; the roller shaft is made of 42CrMo forged parts (diameter ≥ 280mm), with a shell thickness of 22mm. After CNC four-roll rounding processing, the ovality is < 1.2mm; after welding, it undergoes double testing of ultrasonic testing (UT) and magnetic particle testing (MT) to eliminate internal stress, ensuring no deformation when carrying ultra-heavy bulk materials for a long time. ZOOMRY's self-built Quality Testing Center (including an ultra-large structural mechanics laboratory, a hydraulic system ultra-high-pressure testing laboratory, and a mining equipment explosion-proof laboratory) is equipped with more than 60 professional devices. Each ZR160SF Stacker Conveyor must pass 25 strict tests before leaving the factory, such as "3500tph heavy bulk material continuous conveying test", "-40℃ low-temperature startup test", and "120-hour dust environment stability test", to ensure its performance is fully compatible with the ultra-large-scale operation needs of the global mining industry.
The performance design of the ZR160SF Stacker Conveyor fully meets the ultra-large-scale heavy bulk material operation needs of the global mining industry. With its ultra-high-speed throughput of 3500tph and 20m stockpiling height advantage, it has become the "efficiency core" of large open-pit mines and large-scale concentrators.
In the scenario of large open-pit mines, the equipment is mainly used for the transfer and stockpiling of heavy bulk materials between mining areas and crushing stations, handling heavy bulk materials such as iron ore, large coal lumps, and nickel ore (maximum material particle size up to 600mm). Addressing the characteristic of open-pit mines—"daily mining output of over 50,000 tonnes"—the throughput of 3500tph can perfectly match the incoming material rhythm of the front-end large mining conveyors, avoiding the shutdown of the mining line due to slow stockpiling; the 10-20m telescopic boom length can flexibly adapt to the irregular yard of open-pit mines. Combined with the 20m stockpiling height design, it can maximize the use of idle areas in the mine, increasing the stockpiling capacity by 100% compared to traditional stackers and reducing the cost of temporary heavy bulk material transfer (e.g., reducing the use of dump trucks by 40%, saving approximately 80,000 yuan in fuel costs per month); at the same time, the equipment is treated with an anti-corrosion and anti-wear coating (100μm thick), which can resist the erosion of strong ultraviolet rays and high dust in open-pit mines, extending the equipment service life to over 15 years and reducing the replacement frequency of ultra-large-scale mining equipment.
In the scenario of large-scale concentrators, the ZR160SF Stacker Conveyor can be used for the centralized stockpiling of concentrates (such as iron concentrate and copper concentrate) after mineral processing, adapting to the need of "simultaneous material discharge from multiple production lines". The ultra-high-speed throughput of 3500tph can simultaneously receive incoming materials from 3-4 mineral processing lines, avoiding concentrate accumulation and blockage; the PLC fully automatic stockpiling mode can realize partitioned stockpiling of concentrates with different grades. Through precise control of luffing lifting and radial rotation, it avoids material mixing and contamination (grade error can be controlled within 0.5%); the low-noise design (operating noise ≤ 75dB) meets the environmental protection requirements of residential areas around concentrators, avoiding noise complaints; in addition, the equipment can be optionally equipped with a mining dust cover to further reduce dust flying during concentrate stockpiling (dust concentration ≤ 30mg/m³), complying with EU mining environmental protection standards.
| Item | Specification |
|---|---|
| Model | ZR160SF |
| Equipment Type | Ultra-large-scale Stacker Conveyor (Radial Telescopic Stacker) |
| Belt Width (mm) | 1600 |
| Handling Capacity (tph) | 3500 |
| Belt Speed (m/s) | 4.0 |
| Telescopic Boom Length (m) | 10-20 |
| Maximum Stockpiling Height (m) | 20 |
| Radial Rotation Angle (°) | 0-360 (Maximum Steering Angle: 110°) |
| Radial Rotation Speed (°/min) | 0-5 (Adjustable) |
| Hydraulic Oil Tank Capacity (L) | 800 |
| Main Drive Power (kW) | 90 (Main Conveyor) + 30 (Chassis) |
| Hydraulic System Working Pressure (MPa) | 28-32 (Adapted to Ultra-large-scale Operation Needs) |
| Equipment Weight (t) | Approximately 125 (Excluding Optional Accessories) |
| Protection Class | IP54 (Rainproof and Dustproof for Outdoor Use) |
| Explosion-proof Grade (Optional) | Ex d IIB T4 Ga (Mining Explosion-proof) |
| Applicable Ambient Temperature (℃) | -40~70 (Withstands Extreme Climates) |
| Structural Material | Main Structure: Q690 High-strength Alloy Steel |
| Optional Configurations | Heavy-duty Track Tail (Ground Pressure 0.06MPa), Mining Dust Cover, Belt Tear Detection System, Anti-freeze Heating System, Central Control Linkage Module, Explosion-proof Control System |
By choosing the ZR160SF Stacker Conveyor, global mining customers can obtain significant value from three core dimensions: "equipment investment, site utilization, and labor costs". At the equipment level, the ultra-high-speed throughput of 3500tph can reduce equipment investment by 50%, lowering initial procurement costs; at the site level, the 20m stockpiling height design increases yard utilization by 100%; at the labor level, PLC fully automatic stockpiling replaces 8-10 operators. In addition, the annual equipment failure rate is less than 0.1%, and the Mean Time Between Failures (MTBF) reaches over 12,000 hours, reducing downtime losses by 70% compared to the industry average. Based on a throughput of 3500tph, it can reduce annual downtime losses by approximately 1.2 million yuan.
In response to the service needs of global mining ultra-large-scale projects, ZOOMRY has established a comprehensive support system of "ultra-large-scale technology + on-site service + spare parts": It provides multi-language exclusive technical documents for ultra-large-scale mining equipment (including ultra-large structural maintenance guides, mining explosion-proof operation specifications, and troubleshooting manuals) and installation videos, 24/7 online technical consultation, with an engineer response time of no more than 3 hours. The assigned engineers all have over 15 years of service experience in mining ultra-large-scale equipment, capable of accurately solving technical problems in mining operations (such as low-temperature startup failures and control system malfunctions caused by dust); for key mining projects, engineers can be dispatched to the site to conduct "ultra-large-scale equipment installation guidance + mining explosion-proof operation training" (15-day training duration, covering ultra-large-scale equipment safe operation, explosion-proof maintenance, emergency handling, etc.), ensuring that the customer's team fully masters the equipment operation skills; it stocks key spare parts such as ultra-large hydraulic cylinders, heavy-duty idlers, and explosion-proof drive motors, with a delivery cycle of no more than 5 days, significantly shortening the maintenance waiting time of ultra-large-scale equipment and ensuring the long-term stable operation of global mining projects.
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