1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare stilstand erodeer jou projekmarges? Vir aanlegbestuurders en verkrygingspesialiste, the core crushing stage is often the primary bottleneck. Algemene uitdagings met suboptimale klipbrekermasjiene sluit in:

Oormatige dra & Component Failure: Premature wear on liners, kake, or cones leads to frequent, unplanned stoppages for replacement, costing thousands in parts and lost production daily.
Inkonsekwente uitset & Produk kontaminasie: Poor crushing chamber design or unstable operation results in offspec product gradation, increasing recirculation load and reducing saleable material yield.
Hoë energieverbruik: Inefficient drive systems and poor power utilization directly inflate your kWhperton cost, a significant variable in highvolume operations.
Difficult Maintenance & Veiligheidsrisiko's: Kompleks, timeconsuming maintenance procedures require extended downtime and expose technicians to unnecessary hazards during liner changes or clearing blockages.
Infrastructure Rigidity: Vaste brekers het nie mobiliteit vir multisite-projekte nie, while poorly designed mobile units compromise on stability and throughput.

Is your current equipment delivering predictable tonnage at a controlled cost per ton? The solution requires a machine engineered not just to crush rock, but to crush operational inefficiency.

2. PRODUK OORSIG

The FabriCore HD Series Jaw Crusher is a heavyduty, primary crushing station engineered for highabrasion quarrying, mynbou, en sloping herwinning aansoeke. Dit is ontwerp as 'n robuuste, stationary solution for operations prioritizing maximum uptime and lowest costperton over mobility.

Operasionele werkvloei:
1. Voerinname: Oversized raw feed (ROM) is delivered via dump truck or loader into the vibratory grizzly feeder.
2. Primêre vermindering: Material enters the deep crushing chamber where a powerful elliptical jaw motion applies compressive force against a fixed jaw plate.
3. Gradasiebeheer: Gebreekte materiaal kom uit deur 'n verstelbare afvoeropening (CSS), determining the maximum product size.
4. Ontslag & Transport: Sized material is discharged onto the integral product conveyor for transport to secondary processing or stockpiling.

Toepassingsomvang: Ideaal vir harde rock (graniet, basalt), abrasive ore, en gewapende beton sloping puin. Suited for fixedplant installations with expected annual production exceeding 500,000 ton.

Sleutelbeperkings: Not designed as a mobile trackmounted unit. Requires stable concrete foundation and appropriate feed system engineering. Maximum recommended feed size is 85% van die voeropeningsafmeting.

3. KERNKENMERKE

Monoblock Fabricated Frame | Tegniese basis: Highstrength, welded steel construction with finite element analysis (FEA) optimalisering | Bedryfsvoordeel: Eliminates stress points and frame fatigue cracking common in bolted designs; ensures longterm alignment of crushing components | ROI impak: Reduces structural repair costs by an estimated 60% over the crusher's lifespan; extends service life beyond industry average.

Hidrostatiese aandrywingstelsel | Tegniese basis: Direct hydraulic drive with variable displacement motors | Bedryfsvoordeel: Provides smooth startup under full load, reversible operation for clearing blockages, and infinite CSS adjustment under load | ROI impak: Lowers peak electrical demand; reduces mechanical transmission wear; increases operational availability by enabling quick clearing of stalls.

Toggle System with Pressure Relief | Tegniese basis: Hydraulic toggle cylinder with integrated nitrogen accumulator overload protection | Bedryfsvoordeel: Automatically releases tramp metal or uncrushables without shearing pins or requiring manual intervention | ROI impak: Prevents catastrophic damage to other components; field data shows a reduction in tramp ironrelated downtime by over 90%.

Liner Lifetime Optimization | Tegniese basis: Computeraided chamber profile design and reversible/interchangeable manganese steel liners | Bedryfsvoordeel: Promotes interparticle crushing for better shape; allows use of both liner ends before replacement; simplifies inventory | ROI impak: Increases liner life by 1530%; reduces consumable costs per ton crushed.

Gesentraliseerde smeerpunt | Tegniese basis: Singlepoint connection to a network of lubrication lines for all major bearings | Bedryfsvoordeel: Aktiveer veilige, rapid greasing during scheduled stops without dismantling guards; ensures consistent bearing protection | ROI impak: Cuts routine lubrication service time by half; extends critical bearing service intervals.

Geïntegreerde motormontering & Gordelwag | Tegniese basis: Factoryaligned motor base and fully enclosed,

bolton belt guard assembly | Bedryfsvoordeel: Eliminates field alignment issues; provides superior operator safety and contains dust around the drive | ROI impak: Reduces installation/commissioning time; minimizes risk of injuryrelated stoppages.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Competitive Jaw Crusher) | FabriCore HD Series Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Liner ChangeOut Tyd| 1824 ure (stilstand) | < 12 ure (stilstand) | ~45% faster |
| Kragverbruik| Fixed speed motor / Vriemaandrywing| Hydrostatic direct drive with loadsensing control| Tot 12% laer kWh/ton |
| Tramp Iron Recovery Time| Manual pin removal / cutting torch (24 uur)| Hydraulic toggle reversal from operator station (<10 min)| ~95% faster |
| Frame Structural Warranty| 13 years standard warranty on frame/weldments| Lifetime warranty against defects in materials/workmanship| Definitive longterm assurance |
| Beskikbaarheid (Optyd)| Industry target ~8590% (geskat)| Fieldreported >94% in comparable applications| ~5% absolute increase |

5. TEGNIESE SPESIFIKASIES

Model Featured: FabriCore HD4862
Voer opening: 48" x 62" (1200mm x 1500 mm)
Maksimum voergrootte: 41" (1050mm)
Geslote kant-instelling (CSS) Reeks: 6" 14" (150mm 350mm)
Kapasiteitsreeks (@ gedefinieer CSS): 450 1,200 STPH (afhanklik van voermateriaal & gradasie)
Dryfkragvereiste: Vlak IV finaal / Stage V compliant diesel engine OR electric motor option:
Electric Motor Option: 300 HP (225 kW), 460V/60Hz/3Ph
Totale gewig (Breker + Voeder + Vervoerband): Ongeveer. 185,000 lbs (84,000 kg)
Sleutel materiaal spesifikasies:
Frame Steel: ASTM A572 Grade 50
Jaw Liners: Austenitiese mangaanstaal (14%18%)
Main Shaft Forging: Highalloy steel, ultrasonic tested
Draerhuise: Cast ductile iron
Omgewingsbedryfsreeks: 20°C tot +50°C (4°F tot +122°F). Dust suppression kit recommended for arid environments.

6. TOEPASSINGSSCENARIO'S

Granite Quarry Primêre Crushing Station

Uitdaging:
A southeastern US granite quarry faced recurring frame weld failures on their primary jaw crusher after just four years of service. Unplanned downtime for repairs exceeded two weeks annually alongside high energy costs from an inefficient drive system.
Oplossing:
Replacement with a FabriCore HD4862 Jaw Crusher featuring the monoblock fabricated frame and hydrostatic drive system.
Resultate:
Zero structural issues reported after five years of operation. Energy monitoring showed an average reduction of $18 per operating hour in power costs at peak rates. Annual availability increased from approximately $86\%$ aan $95\%$.

Urban Demolition Recycling Hub

Uitdaging:
A contractor processing reinforced concrete from urban demolition struggled with frequent stallouts due to uncrushable rebar mats embedded in slabs. Each event required a full shutdown and dangerous manual torchcutting work inside the chamber.
Oplossing:
Installation of a FabriCore HD3650 Jaw Crusher equipped with the hydraulic toggle pressure relief system.
Resultate:
The system automatically detects overloads and reverses to eject uncrushables within one minute via remote control from the operator cabin. This eliminated an average of three manual interventions per week—reducing safety risk—and increased daily throughput by preventing extended stoppages.

7. KOMMERSIËLE OORWEGINGS

Our pricing structure is based on transparent configuration:

Basistoerustingvlak ($XXXk $XXXk): Includes core FabriCore HD crusher with standard manganese liners,
electric motor drive option,
and basic controls.

Optional Feature Packages:
Outomatisering pakket ($XXk): Includes CSS adjustment via PLC,
dra moniteringssensors,
remote diagnostics port.
HeavyDuty Abrasion Pakket ($XXk): Upgraded liner alloys,
additional wear plates at critical impact points,
ceramiclined feed chute sections.

Service Agreements:
1.Planned Maintenance Plan ($Xk/year): Geskeduleerde inspeksies,
lubrication kits,
prioriteit tegniese ondersteuning.
2.Comprehensive Uptime Plan ($XXk/year): Includes all planned maintenance plus discounted parts pricing up to $40\%$ off list price,
guaranteed emergency parts dispatch within $24$ ure.

Financing Options are available through our industrial partners including operating leases ($36$60 maand terme),
toerusting lenings,
and leasetopurchase agreements designed to preserve capital expenditure budgets.

(Let wel: Specific pricing figures are omitted here as they vary based on final specification,
currency region,
and market conditions.)

8\. FAQ\\\\\\\\\\\\\\\\n\n\Q1\. How does this machine integrate into my existing plant flow\? \\nA\. The FabriCore HD Series is designed as a modular primary station\. We provide detailed interface drawings \(feed height\, discharge height\, footprint\, power connection points\) during the quotation phase\. Our engineering team can review your existing layout to ensure compatibility\.

\Q2\. What is the expected operational cost per ton crushed\? \\nA\. While site\specific\, industry testing demonstrates that operators typically achieve between \$10\%\15\%\$ lower total cost\per\ton compared to previous generation jaw crushers\. This stems from reduced energy consumption\, longer liner life\, higher availability\.

\Q3\. Are spare parts readily available internationally\? \\nA\. Yes\. We maintain regional inventory hubs on three continents\. For critical wear parts \(liners\) we guarantee stock availability against your serial number upon request\.

\Q4\. What training do you provide for our maintenance crew\? \\nA\. We include comprehensive onsite commissioning training covering operation\, daily checks\, routine maintenance procedures like greasing \,liner change protocols using our tooling system\.

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