1. PYNPUNT GEDREWE OPENING

Is stygende bedryfskoste en onvoorspelbare stilstand besig om jou totale of mineraalverwerkingsmarges te erodeer? Vir aanlegbestuurders en ingenieurskontrakteurs, die primêre verpletteringstadium is dikwels die bron van kritieke knelpunte. Algemene uitdagings sluit in:
Oormatige stilstand vir instandhouding: Gereelde voeringveranderings en onverwagte meganiese foute stop jou hele produksielyn, duisende per uur in verlore deurset kos.
Hoë slytasiedeelverbruik: Aggressive or abrasive feed material leads to premature jaw plate wear, verhoog jou koste en skep kopseer vir voorraadbestuur.
Inkonsekwente produkgradering: A worn or poorly designed crusher chamber fails to maintain a consistent CSS (Geslote kant-instelling), resulting in offspec product and recrushing cycles.
Rigid Infrastructure Demands: Many jaw crushers require extensive, costly foundations and are not suited for modular or semimobile plant designs, operasionele buigsaamheid beperk.
Energie ondoeltreffendheid: Older designs with inefficient kinematics consume more power per ton of processed material, 'n direkte impak op jou winspunt.

What if your primary crusher could deliver predictable maintenance intervals, reduce wear costs by a measurable percentage, and adapt to evolving site requirements? The solution requires an engineered approach focused on reliability and total cost of ownership.

2. PRODUK OORSIG

The Bespoke JC5000 is a heavyduty, enkelvoudige kakebeenbreker ontwerp vir primêre vergruising met hoë kapasiteit in steengroef, mynbou, en sloping herwinning aansoeke. Its design prioritizes mechanical robustness and operational efficiency for processing hard rock, erts, en beton.

Operasionele werkvloei:
1. Voerinname: Groot voermateriaal (tot 1300 mm) is delivered via dump truck or wheel loader into the vibratory grizzly feeder (opsioneel), wat boetes omseil om kamerlaai te optimaliseer.
2. Verpletterende Aksie: Materiaal gaan die diep in, nie-verstikkende breekkamer. The aggressive elliptical stroke of the singletoggle mechanism applies high inertia forces to reduce material by compression.
3. Ontslag & Transport: Crushed product exits at the bottom discharge point with a consistent gradation, ready for secondary processing via conveyor.

Toepassingsomvang: Ideal for hightonnage primary crushing stations processing granite, basalt, ystererts, en herwonne beton. Nie aanbeveel vir taai nie, plastic clays or as a standalone unit for producing fine sand specifications without downstream crushing stages.

3. KERNKENMERKE

Diepkamermeetkunde | Tegniese basis: Geoptimaliseerde kneephoek en lang drukslag | Bedryfsvoordeel: Verhoogde kapasiteit per slag en verminderde risiko van oorbrugging/verstikking by die voeropening | ROI impak: Hoër gemiddelde deurset (tph) maximizes plant utilization

HeavyDuty Roller Bearing Design | Tegniese basis: Sferiese selfbelynde rollaers op hoofas | Bedryfsvoordeel: Hanteer hoë radiale en drukbelastings met groter doeltreffendheid as brons busse | ROI impak: Lower friction reduces power draw by approximately 812% versus comparable bushing designs

Hidrouliese CSS-aanpassing & Oorladingsbeskerming | Tegniese basis: Geïntegreerde hidrouliese silinders vir skakelplaatspanning | Bedryfsvoordeel: Closed Side Setting can be adjusted quickly under load; system automatically releases to clear tramp metal | ROI impak: Minimizes unplanned stops for clearing blockages; allows rapid product size changes with less operator intervention

BoltIn Wedge Lock Jaw Plate System | Tegniese basis: Mechanically locked wedge system without epoxy backing material | Bedryfsvoordeel: Jaw plate changeout time reduced to under 4 hours with standard site tools | ROI impak: Direct labor savings during maintenance windows; verhoog plant beskikbaarheid

Modulêre raamkonstruksie | Tegniese basis: Fabricated steel sections with precision machined locating pads | Bedryfsvoordeel: Vereenvoudig vervoer, verminder fondamentvereistes, and allows for future relocation or plant reconfiguration | ROI impak: Lower capital expenditure on civil works; preserves asset value through redeployability

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Vergelykbare klas) | Op maat JC5000 oplossing | Voordeel (% verbetering) |
| : | : | : | : |
| Gemiddelde Liner Life (Skuur graniet) | 180,000 220,000 ton | 260,000 300,000 ton | +30% verlengde dienslewe |
| Kragverbruik per ton gebreekte| ~0,85 kWh/t | ~0.75 kWh/t| ~12% reduction in energy cost |
| Gemiddelde tyd tussen mislukking (MTBF) Hoofkomponente| ~2 000 uur| ~2 800 uur| +40% toename in betroubaarheid |
| Totale instandhoudingsure per jaar Geskeduleer & Ongeskeduleer| Geskatte 120150 ure| Geskatte 80100 ure| Tot 33% reduction in labor |

5. TEGNIESE SPESIFIKASIES

Voer opening: 1300mm x 1000 mm (51" x 40")
Maksimum voergrootte: 1100mm randlengte (43")
Geslote kant-instelling (CSS) Reeks: 150mm 300 mm (6" 12")
Kapasiteitsreeks (Wissel volgens materiaal & CSS): 450 850 ton per uur
Dryfkragvereiste: 200 kW (268 HP) elektriese motor
Totale gewig (Slegs breker): Ongeveer 62,000 kg
Sleutel materiaal spesifikasies:
Hoofraam: Hightensile steel plate (Grade S355J2)
Swing Jaw Die: Mangaan staal (14% Mn), omkeerbaar
Eksentrieke skag: Forged alloy steel EN24T
Bedryfstemperatuurreeks: 25°C tot +45°C (13°F tot +113°F)

6. TOEPASSINGSSCENARIO'S

Granietsteengroef Uitbreidingsprojek

Uitdaging: An existing quarry needed to increase primary circuit output by 35% but had limited space for new foundation works. Downtime during installation was also a critical constraint.
Oplossing: Implementation of a modular Bespoke JC5000 jaw crusher on a prefabricated support structure with a lowprofile hopper.
Resultate: Installation was completed in 40% less time than traditional methods due to simplified foundations. The plant achieved the target throughput increase of 35%, with energy monitoring showing a 9% reduction in specific power consumption compared to the older unit.

Opgradering van ysterertsverwerkingsaanleg

Uitdaging: Excessive wear on jaw plates from highly abrasive ore resulted in liner changes every six weeks at significant cost and production loss.
Oplossing: Replacement of an older doubletoggle crusher with the Bespoke JC5000 featuring its boltin wedge system and optimized chamber geometry.
Resultate: Field data shows jaw plate life extended from an average of six weeks to nine weeks—a 50% improvement—reducing annual liner costs by onethird. The hydraulic adjustment system also allowed operators to compensate for wear more effectively between changes.

7. KOMMERSIËLE OORWEGINGS

The Bespoke JC5000 is offered in three configured tiers:
1. Basis Eenheid Tier: Includes core crusher assembly with standard motor drives and basic instrumentation.
2. Plantgereed-vlak: Integrates matched grizzly feeder product conveyor walkways ladders safety guards motor starters PLC control panel
3. Modular SkidMounted Tier Full semimobile package on a heavyduty skid frame requiring only hookup to power utilities

Optional features include automated lubrication systems dust suppression kits various jaw plate tooth profiles feed chute extensions

Service packages are available from annual inspection plans comprehensive partsandlabor maintenance agreements Extended warranty coverage up five years is offered subject specific operating conditions Financing options including operating lease capital lease loan structures can be structured over terms three seven years align investment cash flow generation

8 Gereelde vrae

Q What existing secondary tertiary equipment compatible JC5000?
A The JC5000 designed produce well graded feed material typical cone impact crushers Its discharge setting range gradation curve data provided ensure compatibility your downstream circuit

Q How does hydraulic adjustment system affect daily operation?
A Operators can check adjust crusher setting minutes using remote station reducing need enter equipment area making product size adjustments responsive market demands

V Watter tipiese lewering tyd aflewering ingebruikneming?
A Standard units have lead time months from order confirmation Full modular plants require additional engineering Site commissioning supervised our engineers typically requires five seven working days

Q Are wear spare parts readily available globally?
A Yes standardized components common consumables like jaw plates side liners held regional distribution centers ensuring availability Critical bearing shaft assemblies available under expedited shipping programs

Q Can this crusher integrated into existing automated control system?
A Yes the JC5000 equipped standard Modbus RTU communication protocol allowing integration most SCADA PLC systems monitoring key parameters like power draw hydraulic pressure provide performance data