1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare beskikbaarheid erodeer jou primêre vergruiskring se winsgewendheid? Vir aanlegbestuurders en ingenieurskontrakteurs, die roterende breker is 'n kritieke bate waar mislukkings eksponensiële gevolge het. Algemene uitdagings sluit in:
Ongeskeduleerde stilstand: Bearing failures or mainshaft issues can halt entire processing lines for days, costing hundreds of thousands in lost production.
Hoë instandhoudingskoste: Gereeld, laborintensive liner changes and component wear directly impact maintenance budgets and manpower allocation.
Inkonsekwente deurset: Poor feed distribution or worn crushing surfaces lead to product gradation fluctuations, downstream bottlenecks, and reduced overall plant efficiency.
Energie ondoeltreffendheid: Older or poorly optimized designs consume excessive power per ton of processed material, a fixed cost that directly affects operating margins.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The answer lies in a purposeengineered gyratory crusher from a dedicated private label manufacturer focused on R&Ddriven performance.

2. PRODUK OORSIG

This product is a highcapacity primary gyratory crusher, engineered for private label partners who require robust, applicationspecific solutions for largescale mining and aggregate operations. Its design focuses on delivering maximum availability and optimal reduction ratios for hard, abrasive ores and rock.

Operasionele werkvloei:
1. Voeraanvaarding: Oversize material from haul trucks or loaders is directed into the steepsided feed hopper.
2. Verpletterende Aksie: The hydraulically adjusted mainshaft assembly gyrates within the concave liners, applying compressive force to reduce material size.
3. Ontslag: Crushed product exits through the discharge opening at the bottom of the crushing chamber, with size controlled by the hydraulic setting adjustment system.
4. Materiaalhantering: The product is conveyed to downstream secondary crushing or screening circuits.

Toepassingsomvang & Beperkings:
Omvang: Ideaal vir hoëtonnage (2,000+ TPH) primary crushing applications in metal ore mines (koper, yster, goud), large quarries producing aggregate, and major construction projects requiring onsite primary reduction.
Beperkings: Nie geskik vir laetonnage-operasies nie (<500 TPH), recycling applications with high tramp metal content without extensive protection systems, or portable/mobile plant installations due to size and weight.

3. KERNKENMERKE

Gepatenteerde konkawe profiel | Tegniese basis: Optimized crushing chamber geometry based on discrete element modeling (DEM) | Bedryfsvoordeel: Delivers a consistent chokefed crushing action for uniform wear and stable product gradation | ROI impak: Extends liner life by an average of 1520%, reducing liner cost per ton and changeout frequency

Integrated Smart Bearing System | Tegniese basis: Multisensor monitoring of bearing temperature, vibrasie, and lubrication pressure | Bedryfsvoordeel: Provides early warning diagnostics to prevent catastrophic bearing failure | ROI impak: Eliminates unplanned downtime events related to bearing issues, protecting millions in potential production losses

Hydraulic Setting & Oorladingsbeskerming | Tegniese basis: Dualfunction hydraulic cylinder for precise CSS adjustment and automatic relief under uncrushable material | Bedryfsvoordeel: Allows operators to adjust product size remotely and protects the crusher from mechanical damage | ROI impak: Reduces setting time by 70% compared to manual systems and prevents costly repairs from tramp steel events

TopService Ontwerp Filosofie | Tegniese basis: All routine service tasks (voering veranderinge, spider arm refurbishment) accessible from above | Bedryfsvoordeel: Eliminates the need for personnel to work beneath suspended components or dismantle the crusher structure | ROI impak: Verminder geskeduleerde instandhoudingstyd met tot 50%, enhancing plant availability

Direkte ry & Torque Limiter System | Tegniese basis: Lowspeed synchronous motor coupled via an air clutch with torque limiter | Bedryfsvoordeel: Provides smooth startup under load capability and protects drive train from shock loads | ROI impak: Reduces electrical stress during startup by 60% versus VFDonly solutions, lowering peak demand charges

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard Norm | This Gyratory Crusher Solution | Gedokumenteerde voordeel |
| : | : | : | : |
| Meganiese beskikbaarheid (Teiken) | 92 94% | >96% (Contractual Target) | +24 persentasiepunte |
| Liner Life (Skuurerts) | ~6 maande (Wissel) | 78 Maande (Average Field Data)| +1520% Verbetering |
| Spesifieke energieverbruik (kWh/t) ~0,8 1.2 kWh/t ~0.7 0.9 kWh/t ~1015% Improvement |
| CSS-aanpassingstyd <4 Ure 75% Vinniger |
| Totale koste van eienaarskap (5Year Projection)| Baseline Model Averages +1218% Laer TCO |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 2,000 oor 10,000 metrieke ton per uur (tph), depending on model size and feed material.
Motor Krag: Standaard dryf vanaf 450 kW tot 1 MW+; engineered to client specifications.
Voer opening: Gaping groottes van 1,300 mm aan 1,800 mm available.
Materiaalspesifikasies:
Hoofraam & Head Center: Highstrength cast steel alloy.
Konkaaf & Mantle Liners: Mangaan staal legerings; optional premium alloys for specific abrasion/impact conditions available.
Hoofskag: Forged alloy steel with precision machining.
Fisiese afmetings & Gewig: Significant footprint; exact dimensions provided per model. Approximate installed weights range from 350 ton tot oor 800 ton.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 40°C tot +50°C met toepaslike smeerstelsels; stof verseëling standaard.

6. TOEPASSINGSSCENARIO'S

Kopermynuitbreiding

Challenge A Tier1 copper operation needed to increase primary circuit throughput by 25% without expanding their truck fleet or dump pocket footprint. Their existing crusher was a bottleneck with frequent linerrelated downtime.

Solution Implementation of our largestcapacity gyratory crusher model featuring the patented concave profile for higher reduction ratio in a single pass.

Resultate Deurset het met 28%. Liner life improved from an average of approximately five months to sixandahalf months under identical ore conditions. Annual production targets were met three weeks ahead of schedule following commissioning.

Granite Quarry Primary Circuit Upgrade

Challenge A major aggregate producer faced volatile energy costs and high maintenance expenses on their aging primary crusher. Product consistency was also an issue affecting their premium product lines.

Solution A midrange gyratory crusher was selected with a focus on energy efficiency via direct drive optimization and superior chamber geometry.

Results Specific energy consumption decreased by an average of approximately twelve percent yearoveryear despite increased operating hours.The consistent gradation reduced recirculating load in secondary circuits by nearly eighteen percent.The quarry reported meeting tighter specification bands more reliably for key customer contracts.

7. KOMMERSIËLE OORWEGINGS

Our private label manufacturing model provides flexible commercial pathways tailored for OEMs and largescale endusers:

Prysvlakke: Structured around core model size (voer opening), drive power rating,and level of standard automation.Control system integration is offered as either basic local control or full PLC/SCADA interface packages.

Opsionele kenmerke & Opgraderings: Key options include advanced predictive maintenance sensor suites,dust suppression ring kits,material level monitoring systems,and proprietary wearresistant alloy packages for liners.

Dienspakkette: Available service agreements range from basic technical documentation support through comprehensive multiyear performance contracts covering planned maintenance,inspections,and guaranteed parts availability with defined response times.

Finansieringsopsies: We work with established financial partners ableto structure leasing arrangements,tailored payment plans aligned with project milestones,and other financing solutions upon request.This facilitates capital budget planningfor our clients' projects.

8.Gereelde vrae

V:What levelof engineering supportis provided duringthe integrationof thisgyratorycrusherintoan existingplantlayout?
A OurR&Dandapplicationengineeringteamsworkdirectlywithyourprojectengineersto reviewfoundationdesignsfeedanddischargearrangementsandinterfacingwithexistingconveyorsystemsWe providecomprehensivelayoutdrawingsforcesandloaddatato ensureproperintegration

V:Canyourcrushersbeconfiguredtooperatewithautomationsystemssuppliedbyothervendors?
A YesThecorecrushercontrolsystemisdesignedwithstandardindustrialcommunicationprotocols(egOPCUAProfibusEthernet/IP)allowingforseamlessdataintegrationintoplantwideprocesscontrolandmonitoringsystems

V:Whatisthetypicalleadtimefromordertocommissioningforastandardmodel?
A Leadtimesvarybymodelsizeandcustomizationbutgenerallyrangefrom12to18monthsforcompletecrushersupplyincludingengineeringmanufacturingfactorytestinganddeliverySchedulesareconfirmeduponprojectkickoff

V:Aretheredocumentedcasesofretrofittingyourcrushingchambertechnologyintoexistinggyratorycrushersfromothermanufacturers?
A WhileourprimaryfocusisnewunitswehaveexecutedseveralsuccessfulmodernizationprojectsforcompatiblelegacycrushersTheseinvolvereplacingkeywearcomponentsandsometimeshydraulicsystemstodeliverperformanceimprovementsAcasestudyreviewcanbe provideduponrequest

V:Whatdefinesthe"TotalCostofOwnership"advantageinyourcomparisons?
A OurTCOanalysisovera5yearperiodaccountsforinitialcapitalcostenergyconsumptionprojectedwearpartslifeandreplacementcostsscheduledmaintenancelaborhoursandexpectedavailabilitylossesFielddatafromsimilarenvironmentsformsthebasisfortheseprojections

V:Doyouoffertestcrushingofcustomermaterialsamplespriorto purchase?
A YesWeoperateapilotscalecrushingfacilityandcanperformcomprehensivematerialtestworkincludingabrasivenessandcompressionstrengthanalysisto validatecapacitymodelingandliner liferecommendationsThisdataisincludedinourtechnicalproposal

V:Whatarethestandardwarrantytermsforthemainmechanicalcomponents?
A Themainstructuralcomponents(mainframeheadcenter)mainshaftassemblyandbearingscarryastandardwarrantyof24monthsfromcommissioningor26monthsfromshipmentwhicheveroccurfirstsubjecttocorrectinstallationoperationasperourmanuals