H1: Optimize Your Quarry Output with Advanced Limestone Crushing Solutions

1. PYNPUNT GEDREWE OPENING

Managing a limestone quarry’s primary crushing station is a critical bottleneck. Inconsistent feed, abrasive material, and relentless operational demands translate directly into profit erosion. Staan jy voor hierdie aanhoudende uitdagings?
Ongeskeduleerde stilstand: Unplanned stoppages due to crusher blockages, wearrelated failures, or component breakdowns halt your entire downstream process. Industry averages indicate that each hour of primary crushing downtime can cost over $5,000 in verlore produksie en arbeid.
Hoë bedryfskoste: Premature wear on manganese steel jaws and liners requires frequent, costly replacements. Inefficient power draw from poorly matched or outdated crushers inflates your energy expenditure, one of the plant's highest variable costs.
Inconsistent Product Sizing: Variability in feed size and moisture content leads to uneven discharge from the primary crusher. This places undue stress on secondary and tertiary stages, reducing their efficiency and compromising final product gradation.
Rigid Setup Limitations: Fixed primary crusher installations lack the flexibility to adapt to changing face locations or varying geology, leading to extended rehandling with loaders and increased fuel costs.

The central question for plant managers is clear: how can you achieve higher throughput with greater reliability while controlling the costperton metric?

2. PRODUK OORSIG

Die Mobile Primary Jaw Crusher represents a paradigm shift in initial limestone size reduction. This selfcontained trackmounted unit integrates a highcapacity jaw crusher, vibrerende grizzly feeder, and onboard power system into a single mobile platform.

Operasionele werkvloei:
1. Direct Face Feeding: The unit positions directly at the quarry face or shot pile, minimizing haulage distance for excavators or wheel loaders.
2. Integrated PreScreening: The aggressive grizzly feeder bypasses fines directly to the discharge conveyor, reducing crusher cavity wear and increasing effective capacity.
3. Primêre verplettering: A robust jaw crusher reduces runofquarry limestone to a consistent nominal size suitable for conveyor transport to secondary processing.
4. Direct Discharge: Crushed material is conveyed to either a stockpile or directly into the feed hopper of your downstream plant.

Toepassingsomvang & Beperkings:
Omvang: Ideal for largescale quarrying operations, mining contracts requiring relocation, and operations with multiple faces or satellite deposits. Optimal for limestone with a compressive strength below 250 MPa.
Beperkings: Not designed for highly abrasive silicified limestone without specific liner options. Maximum feed size is governed by crusher model dimensions; oversize boulders require prebreaking.

3. KERNKENMERKE

Direct Feed Optimization | Tegniese basis: Integrated vibrating grizzly feeder (VGFF VGF) with bypass chute | Bedryfsvoordeel: Verwyder fyn stowwe voor fyngedruk, reducing chamber wear and preventing packing | ROI impak: Velddata wys tot 15% reduction in liner wear costs and a 1020% increase in effective throughput.

Hidrouliese verstelling & Skoonmaak | Tegniese basis: PLCcontrolled hydraulic system for CSS adjustment and uncrushable release | Bedryfsvoordeel: Enables quick product size changes and automatic clearing of stall events without manual intervention | ROI impak: Reduces adjustment time by 90% versus manual shims; prevents major downtime from tramp metal events.

DieselElectric Hybrid Drive | Tegniese basis: Vlak 4 Final diesel engine generating power for allelectric crusher & conveyor drives | Bedryfsvoordeel: Eliminates clutch/belt maintenance; provides optimal torque at variable speeds; significantly quieter operation | ROI impak: Bedryfstoetsing demonstreer tot 25% lower fuel consumption compared to direct dieselhydraulic drives.

Advanced Wear Part Design | Tegniese basis: Computermodeled jaw die profiles using ultrahigh tensile manganese steel | Bedryfsvoordeel: Achieves more interparticle crushing for better shape, extends service life through optimized kinematics | ROI impak: Increases wear life by an average of 30%, lowering costperton for consumables.

Intelligent Process Control (IPC) Stelsel | Tegniese basis: CANbus system monitoring load, krag trek, temperatuur, and feed level | Bedryfsvoordeel: Automatically regulates feeder speed to maintain optimal cavity fill and protects against overloads | ROI impak: Maximizes throughput while preventing damage; operator telemetry reduces troubleshooting time.

Rapid Relocation Capability | Tegniese basis: Trackmounted chassis with hydraulic setup functions (folding conveyors/hydraulic legs) | Bedryfsvoordeel: Full relocation between faces can be completed in under 30 minutes by a single operator | ROI impak: Eliminates need for multiple fixed plants; enables singleunit coverage of large or complex sites.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Fixed Plant) | Mobile Primary Jaw Crusher Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Setup/Relocation Time| Dae (civil works required) | 95% Vinniger |
| Fuel Consumption per ton| Basislyn (Loader haulage + fixed plant) | Direct face feeding + hybrid drive| Tot 25% Vermindering |
| Liner Wear Life (Mn14%)| Standard profile design| Optimized computermodeled profile| ~30% Extension |
| Operasionele buigsaamheid| Fixed location; limited feed points| Follows the face; multiple deposit sites| Transformational |
| Labor for CSS Adjustment| Manual shim adjustment (~2 hours)| Hydraulic adjustment via HMI (~5 mins)| ~90% Reduction |

5. TEGNIESE SPESIFIKASIES

Model Reference: MPJC130
Breker tipe: Enkel-wisselkaakbreker
Voer opening: 1,300 x 900 mm
Maksimum voergrootte: 800 mm randlengte
Geslote kant-instelling (CSS) Reeks: 100 250 mm (hydraulically adjustable)
Kapasiteitsreeks (Kalksteen): Tot 600 ton per uur (afhanklik van CSS & materiaal)
Ry stelsel: DieselElectric Hybrid – Tier 4 Final diesel engine generating power for electric crusher motor & vervoerbande.
Main Conveyor: Belt width: 1,400 mm / Discharge height: ~4.2 m (hydraulically adjustable)
Voeder: Vibrerende Grizzly Feeder (VGFF VGF) with integral prescreen section.
Volg Mobiliteit: Hydraulic drive system for onsite movement.
Raam & Komponente: Highgrade structural steel; abrasionresistant steel liners in hopper and chutes.
Bedryfstemperatuurreeks: 20°C tot +45°C
Stofonderdrukking: Integrated spray bar system manifold ready for connection.

6. TOEPASSINGSSCENARIO'S

Large MultiFace Quarry Operation | Challenge A major cement producer needed to reduce haulage costs from three distinct faces over a 2km site area while maintaining consistent feed to their central processing plant.| Solution Deployment of one Mobile Primary Jaw Crusher relocated every 46 weeks between faces based on extraction sequencing.| Results Elimination of two dedicated haul trucks resulted in annual fuel savings exceeding $180k. Consistent primary product improved secondary cone crusher efficiency by an estimated 8%.

New Greenfield Site Development Challenge A contractor won a shortterm mining lease but faced prohibitive capital costs for installing fixed crushing infrastructure.| Solution Utilizing a Mobile Primary Jaw Crusher on a rentalwithpurchaseoption plan provided immediate crushing capability without permanent investment.| Results The site achieved full production within two weeks of equipment arrival. The client processed over 500kt of limestone during the contract period with positive net cash flow from month one.

7. KOMMERSIËLE OORWEGINGS

Our solutions are offered through flexible commercial models tailored to your operational timeline:

Toerustingprysvlakke
Base Configuration MPJC130 Unit
Advanced Package Includes IPC System upgraded dust suppression fan package
Arctic/Package Includes coldweather engine preheaters insulated hydraulics

Optional features include magnetic separators radio remote control extended discharge conveyors

Dienspakkette:
Platinum Support Plan Includes scheduled maintenance parts kits labor priority response guaranteed uptime commitment
Gold Maintenance Plan Covers all scheduled servicing inspections with parts at preagreed rates

Financing Options Available:
Full capital purchase operating lease rental agreements renttoown structures tailored financing can be arranged through our industrial partners

8.Gereelde vrae

What is the typical lead time from order commissioning?
For standard models lead time is typically weeks Custom configurations may require additional time Detailed project planning is initiated upon order

How does this unit integrate with my existing secondary plant?
The unit discharges via an onboard conveyor designed stockpile material or integrate directly into your existing plant feed hopper Conveyor length discharge height are specified during initial consultation

What are the ongoing maintenance requirements?
Daily greasing walkaround checks Weekly inspection of wear parts The IPC system provides predictive maintenance alerts Service intervals are at recommended hour milestones outlined in the support plan

Can it handle other materials besides limestone?
While optimized for limestone applications are possible for other aggregates like granite basalt demolition concrete subject specific model configuration liner selection review

What training is provided operators maintenance staff?
We provide comprehensive onsite operational training technical manuals access our online portal video library Training focuses safe efficient operation basic troubleshooting procedures