1. PYNPUNT GEDREWE OPENING

Is stygende bedryfskoste en onvoorspelbare stilstand besig om die winsgewendheid van jou primêre verpletteringsbaan te erodeer? Vir aanlegbestuurders en ingenieurskontrakteurs, die primêre vergruisingsfase is 'n kritieke bottelnek waar ondoeltreffendheid deur die hele verwerkingslyn val. Algemene uitdagings sluit in:
Oormatige stilstand vir instandhouding: Gereelde voeringveranderings en onverwagte meganiese foute stop produksie, 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: Fluctuations in feed size or hardness result in an uneven discharge product, placing stress on downstream screening and secondary crushers.
Rigiede opstellingsbeperkings: Fixed jaw crushers cannot adapt to changing project demands or feed characteristics, locking you into a single operational profile.

How do you secure consistent throughput while controlling maintenance costs and adapting to variable feed conditions? The solution requires a robust design focused on durability, diensbaarheid, and sustained performance.

2. PRODUK OORSIG

The Bulk JC5000 is a highcapacity, singletoggle jaw crusher engineered for primary crushing in demanding mining, steengroef, en grootskaalse konstruksietoepassings. It processes runofmine rock, gebrande steengroefklip, and demolition concrete into a consistent, growwe aggregaat.

Operasionele werkvloei:
1. Voerinname: Groot materiaal (tot 1300 mm) is directed into the deep crushing chamber by vibrating grizzly feeders.
2. Kompressie verplettering: The elliptical motion of the single toggle forces the movable jaw against the fixed jaw, die toepassing van drukkrag om die rots te breek.
3. Ontslag & Opruiming: Gebreekte materiaal gaan deur die onderste afvoeropening uit (CSS), with the aggressive stroke ensuring efficient clearing even under high load.

Toepassingsomvang: Ideaal vir harde rock (graniet, basalt), skuurerts, and recycled concrete with strengths up to 400 MPa. It serves as the primary workhorse in stationary plants and large mobile tracked setups.

Beperkings: Nie ontwerp vir nat nie, sticky materials that may cause chamber packing without proper feed conditioning. For ultrafine output (<50mm), secondary or tertiary crushing stages are required.

3. KERNKENMERKE

Diepkamerontwerp | Tegniese basis: Optimized nip angle and long linear crushing path | Bedryfsvoordeel: Enables higher volume intake per cycle and reduces bridging risks | ROI impak: Increases potential throughput by up to 15% versus shallower chambers of similar inlet size

Hidrouliese wisselverstellingstelsel | Tegniese basis: Replaceable hydraulic cylinder for tensioning & overload release | Bedryfsvoordeel: Allows remote CSS adjustment under load and protects against tramp metal damage | ROI impak: Verminder onbeplande stilstandtyd met 'n gemiddeld van 30 hours annually related to tramp iron incidents

HeavyDuty Rollager-samestelling | Tegniese basis: Sferiese selfbelynde rollaers op hoofas | Bedryfsvoordeel: Supports higher radial loads and operates at lower temperatures than bronze bushings | ROI impak: Verleng die dienslewe van die laer met ongeveer 40%, verlaging van die vervangingsfrekwensie van deel

BoltOn Wear Liners | Tegniese basis: Modular manganese steel liners on frame sides | Bedryfsvoordeel: Protects crusher frame from abrasion; replaced independently of jaw dies | ROI impak: Preserves structural integrity of main frame for decades, avoiding capital replacement costs

Gesentraliseerde smeerpunte | Tegniese basis: Automated or manual greasing lines routed to all major bearings | Bedryfsvoordeel: Aktiveer veilige, routine lubrication without direct operator access to moving parts | ROI impak: Standardizes preventive maintenance, reducing lubricationrelated failures by over 80%

Reinforced Swing Jaw Design | Tegniese basis: Eindige Element Analise (FEA) optimized cast steel structure with thick ribs | Bedryfsvoordeel: Provides maximum fatigue resistance under cyclic loading stresses | ROI impak: Minimizes risk of catastrophic jaw failure, ensuring multiyear structural service life

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Vergelykbare klas) | Bulk JC5000 Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Average Jaw Plate Life (Skuur graniet) | ~180 000 MTONs per stel (Standard Mn18) | ~250 000 MTONs per stel (Premium Mn22) +38% |
| Tyd vir CSS-aanpassing / Liner Turnover| 46 ure (manual shim adjustment) 900 TPH in field trials| >6% Hoër uitset |

5. TEGNIESE SPESIFIKASIES

Voer opening: 1300mm x 1000 mm (51" x 40")
Maksimum voergrootte: Tot 1100 mm randlengte
Geslote kant-instelling (CSS) Reeks: 150mm 300 mm
Kapasiteitsreeks: Tot 950 ton per uur (afhanklik van voermateriaal & CSS)
Dryfkragvereiste: 132 kW elektriese motor
Totale gewig (Slegs breker): Ongeveer 62 ton
Sleutel materiaal spesifikasies:
Hoofraam: Vervaardigde swaardiens staalplaat
Swaai kakebeen & Fixed Jaw Dies: Premium mangaanstaal
Eksentrieke skag: Gesmede legeringstaal
Bedryfstemperatuurreeks: 30°C to +45°C with appropriate lubricants
Afmetings (L x B x H): ~4m x 3m x 3m

6. TOEPASSINGSSCENARIO'S

Hard Rock Quarry Expansion Challenge:

A granite quarry needed to increase primary circuit output by 25% without expanding its plant footprint or secondary crushing line.

Oplossing:

Two older jaw crushers were replaced with a single Bulk JC5000 unit configured with a wider CSS to produce optimal feed for existing cone crushers.

Resultate:

Deurset het met 28%. The consistent product gradation reduced cycling in downstream cones. Combined with longer wear life on jaw plates,the change lowered costpertonne by an estimated 18%.

LargeScale Mineral Processing Plant Challenge:

An iron ore operation faced excessive unplanned downtime due to tramp steel damaging its primary crusher,losing an average of $15k per incident.

Oplossing:

Implementation of the Bulk JC5000 with its hydraulic toggle system for automatic overload protection.

Resultate:

Field data shows three overload events were safely cleared without shutdown in one quarter.Planned maintenance intervals are now reliably met,directly saving over $60k in avoided downtime within six months.

7. KOMMERSIËLE OORWEGINGS

The Bulk JC5000 is positioned as a capital investment for operations focused on longterm total cost of ownership reduction.

Basis Toerusting Prysvlak: Sluit breker in,motor bevestigings,and drive sheaves.Competitively structured against equivalent OEM offerings.
Opsionele kenmerke & Pakkette:

Prestasiepakket: Includes automated grease system,motor aansitter,and wear part monitoring sensors.
QuickChange Package: Features hydraulic assist tools for jaw die replacement.
Modular Frame Guarding: Preassembled safety guards for faster installation.

Diensooreenkomste:

1Year OnSite Warranty with factory commissioning support.
3Year /5Year Extended Protection Plans covering major components.
Scheduled Inspection Programs managed via predictive maintenance software.

Financing options include equipment leasing through partners,tailored rentaltoown structures for projectbased work,and fleet upgrade programs involving tradeins of legacy equipment.

8.Gereelde vrae

V1:What is the compatibility of the Bulk JC5000 with my existing vibrating grizzly feeder and discharge conveyor?
A1:The JC5000 is designed to standard industry mounting footprints.Its feed height and discharge trajectory can be engineered during quotation to match your current layout.Engineering support is provided for integration reviews.

V2:What is the expected operational impact during liner changeouts?
A2:The design prioritizes service access.Field reports indicate a full set of jaw dies can be changed by a threeperson crew in one shift,a significant reduction compared to older designs requiring torch work or complex dismantling.

V3:What commercial terms are available beyond upfront purchase?
A3.We offer several models including straight capital sale,fixedterm lease financing,and certified refurbished units from our rebuild program.Each has distinct cash flow implications we can detail based on your procurement process.

V4:What power supply infrastructure is required?
A4.The unit requires a dedicated supply compatible with its 132 kW motor.Full electrical schematics,suggested protection devices,and softstart recommendations are provided ahead of installation.A dieselhydraulic drive option exists for remote sites lacking grid power.

V5:Watter opleiding word vir ons instandhoudingspan verskaf?
A5.Comprehensive training modules are included,covershing safe operation,roetine-instandhoudingsprosedures,and basic troubleshooting.This can be delivered onsite during commissioning or at our regional technical centers.Documentation includes detailed parts manuals and taskspecific videos