1. PAINPOINT DRIVEN OPENING

Are your primary crushing operations constrained by inconsistent throughput, excessive liner wear costs, and unplanned maintenance halting your entire processing line? For plant managers and engineering contractors, the bottleneck at the primary stage directly impacts downstream efficiency and overall profitability. Key challenges with conventional primary crushers include:

Unscheduled Downtime: Bearing failures or structural issues can stop production for days, costing tens of thousands per hour in lost output.
High PerTon Wear Costs: Frequent and complex mantle/concave changes consume labor hours and inventory budget, driving up operational expenditure.
Feed Size Limitations: Inability to handle large, slabby feed directly from the face leads to secondary blasting or prebreaking, adding cost and delay.
Inconsistent Product Gradation: Fluctuations in discharge setting affect secondary crusher feed and overall circuit balance, reducing optimal recovery.

Is there a robust solution that delivers higher availability, lower longterm operating costs, and consistent throughput for hard rock mining and largescale aggregate operations?

2. PRODUCT OVERVIEW

The Bespoke Gyratory Crusher is engineered as a heavyduty primary crushing solution for hightonnage, abrasive ore and rock processing. Designed for capital projects demanding decades of reliable service, it transforms runofmine feed into a consistent product for secondary crushing.

Operational Workflow:
1. Feed Intake: Direct dump from haul trucks or loaders into the large gaping feed opening.
2. Crushing Action: The eccentrically mounted main shaft gyrates, compressing material between the fixed concave liners and the gyrating mantle.
3. Discharge: Crushed material exits through the adjustable discharge setting at the bottom of the crushing chamber.

Application Scope: Ideal for largescale hard rock metal mines (copper, iron ore, gold), major quarries producing aggregate for infrastructure, and highvolume mineral processing plants with annual capacities exceeding 1 million tons.

Limitations: Not suitable for lowtonnage operations (< 500,000 tpy), nonabrasive materials like limestone where a simpler crusher may suffice, or sites with extreme space constraints where a mobile primary plant is mandated.

3. CORE FEATURES

Patented Spider Design | Technical Basis: Multiarm forged steel construction with integrated rim liners | Operational Benefit: Eliminates traditional spider bushing wear points and protects the top shell from direct feed impact | ROI Impact: Reduces top service frequency by up to 40%, lowering parts inventory and labor costs.

HydroSet® Chamber Clearing & Adjustment | Technical Basis: Hydraulic piston supporting the main shaft for precise control | Operational Benefit: Allows remote adjustment of crusher setting for product size control and automatic clearing of chamber blockages in minutes | ROI Impact: Minimizes downtime from tramp metal events by over 90% compared to manual clearing.

Lube System with SMART Sensors | Technical Basis: Highflow filtration system with continuous temperature and pressure monitoring | Operational Benefit: Ensures optimal bearing lubrication under all loads; provides early warning diagnostics to prevent catastrophic failure | ROI Impact: Extends major bearing service life; predictive alerts prevent unscheduled stoppages estimated at $250k+ per event.

Concave & Mantle Alloy System | Technical Basis: Proprietary austenitic manganese steel with controlled carbide precipitation | Operational Benefit: Achieves higher workhardening capability for extended wear life in abrasive conditions | ROI Impact: Documented liner life improvements of 1525% over standard alloys, reducing costperton for wear components.

Tubular Frame Mainframe | Technical Basis: Welded steel plate construction with stressrelieving technology | Operational Benefit: Provides superior fatigue resistance and alignment integrity under cyclical loading over decades | ROI Impact: Ensures structural longevity beyond 30 years, protecting capital investment and avoiding premature replacement.

Integrated Maintenance Platform | Technical Basis: Engineered access systems built into the crusher housing | Operational Benefit: Provides safe, efficient access for inspection and liner changes without requiring additional scaffolding | ROI Impact: Reduces planned maintenance window duration by approximately 25%, increasing annual available operating hours.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Bespoke Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Annual) | 92 94% | 96 97%| +35% |
| Total Cost per Ton (Wear Parts) Baseline = 100%| 100% (Baseline) | 78 85%| 15 to 22% |
| Throughput Capacity (tph) for equivalent feed size| Baseline (e.g., 5,000 tph)| 5,400 5,600 tph| +8 to +12% |
| Energy Consumption (kWh/t) at rated capacity| Baseline (e.g., 0.85 kWh/t)| 0.78 0.80 kWh/t| 6 to 8% |
| Major Overhaul Interval (Operating Hours)| ~60,000 hours| 72,000+ hours| +20% |

Data based on field performance audits across comparable installations.

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 10,000 metric tons per hour (tph), depending on model selection and chamber profile.
Feed Opening: Gapes from 1,200 mm to 1,800 mm to accept large runofmine boulders.
Drive Power: Electric motor requirements range from 450 kW to over 1 MW (600 – 1,300 HP). Dual drive options available for highest capacity models.
Material Specifications: Mainframe constructed from ASTM A36/SS400 steel; Highstress components use forged alloy steel; Standard liners are proprietary AMS; Optional alloys available for specific abrasion/corrosion conditions.
Physical Dimensions & Weight: Varies significantly by model. Example (Midrange): Total height ~79m; Installed weight approx. 350 – 550 metric tons including base frame.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust sealing systems standard; optional Arctic or tropical packages available.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A Tier1 copper operation needed to increase plant throughput by 25%. Their existing primary crushers were at capacity limits with frequent liner changes causing weekly downtime.
Solution: Installation of two Bespoke Gyratory Crushers in parallel configuration with automated setting control.
Results: Achieved sustained throughput of 11,500 tph combined. Liner life increased by an average of 18%, reducing planned maintenance events from biweekly to monthly intervals. Plant availability rose by 4%, contributing directly to the targeted production increase.

Granite Quarry Supplying Major Infrastructure Project

Challenge: A quarry contractor faced unpredictable product gradation and high energy costs feeding their secondary cone crushers due to an aging primary jaw crusher.
Solution Replacement with a single Bespoke Gyratory Crusher optimized for aggregate shape.
Results Product consistency improved dramatically (+/10mm variation). Energy consumption per ton dropped by an estimated . The more consistent feed allowed secondary crushers to operate at peak efficiency increasing final chip yield by .

Iron Ore Processing Plant Upgrade

Challenge Severe abrasion led to concave replacement every six weeks at a cost exceeding $120k per change including labor production loss
Solution Retrofit installation of a Bespoke Gyratory Crusher featuring our proprietary alloy concave system
Results Concave service life extended days representing a improvement Total costperton for primary crushing wear parts was reduced by

7 COMMERCIAL CONSIDERATIONS

Pricing is projectspecific based on required capacity drive configuration material specifications

Base Equipment Tier Includes core crusher assembly main motor lubrication system basic instrumentation

Optional Features Advanced predictive monitoring sensors automated setting regulation systems special alloy liner packages custom discharge conveyor designs extended warranty plans

Service Packages Comprehensive offerings include supervised installation commissioning training multiyear scheduled maintenance programs guaranteed parts availability programs

Financing Options Available through partnered financial institutions including lease structures project financing deferred payment plans aligned with project cash flow milestones

A detailed quotation outlining capital expenditure total cost of ownership analysis will be provided following a review of your specific feed material target product size required annual tonnage

FAQ

What is lead time typically?
Lead times vary based on model complexity current manufacturing schedule Standard models require months Custom configurations may require months Detailed schedules are provided upon project commitment

How does integrate into an existing plant?
Our engineering team conducts a full site audit We provide interface drawings foundation requirements dust suppression integration points electrical load data ensure compatibility minimal disruption during installation

What are ongoing operational costs?
Primary costs are power consumption wear liners scheduled maintenance Field data indicates total operating cost typically ranges per ton processed depending on material abrasiveness This includes energy labor parts lubricants filters

What training is provided?
We offer comprehensive onsite operator maintenance training covering daily inspections safe operation troubleshooting procedures liner changeout protocols Training manuals digital resources included

What warranty applies?
Standard warranty covers defects in materials workmanship months operation whichever first Extended component warranties available Structural integrity mainframe carries year limited warranty