Bespoke Jc5000 Jaw Crusher Brochure

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1. PAINPOINT DRIVEN OPENING Are escalating operational costs and unpredictable downtime eroding your aggregate or mining profit margins? Key challenges in primary crushing operations often include: Excessive Downtime for Maintenance: Frequent liner changes and mechanical adjustments halt your entire processing line, costing thousands per hour in lost production. Unplanned Stoppages from Tramp Metal: Unseen contaminants…

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1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mining profit margins? Key challenges in primary crushing operations often include:

Excessive Downtime for Maintenance: Frequent liner changes and mechanical adjustments halt your entire processing line, costing thousands per hour in lost production.
Unplanned Stoppages from Tramp Metal: Unseen contaminants cause significant damage to crusher internals, leading to catastrophic failure and costly repairs.
Inconsistent Product Gradation: Fluctuations in feed material or wear patterns result in offspec product, forcing recrushing and reducing plant throughput efficiency.
High Operational Costs: Rising energy consumption per ton and the frequent replacement of highwear components directly impact your bottom line.
Rigidity to Feed Variations: Fixed geometry crushers struggle with changing feed sizes or material hardness, causing bottlenecks.

Is your primary crusher a reliable asset or a constant source of concern? The solution requires engineering focused on durability, accessibility, and process stability.

2. PRODUCT OVERVIEW

The Bespoke JC5000 is a highcapacity, singletoggle jaw crusher engineered for the most demanding primary crushing applications in mining, quarrying, and heavyduty recycling. Its robust design prioritizes continuous operation with minimal intervention.

Operational Workflow:
1. Feed Intake: Large runofmine or quarryrun material (up to 1300mm) is directed into the deep, nonchoking crushing chamber.
2. Compressive Crushing: The aggressive elliptical motion of the singletoggle jaw applies intense compressive force against the fixed jaw, effectively breaking even the hardest abrasive rock.
3. Discharge & Clearance: Crushed material exits through the discharge opening, with a hydraulic toggle tensioning and release system providing automatic protection against uncrushables.

Application Scope: Ideal for hard rock mining (iron ore, gold bearing ore), granite/basalt quarries, and slag processing. Designed as a stationary primary unit for plants targeting sustained throughputs between 750 1500 mtph depending on material and closed side setting.

Limitations: Not designed for ultrafine product sizing (secondary/tertiary roles) or processing of wet, sticky materials without prior scalping. Requires a solid foundation and appropriate feed system integration.

3. CORE FEATURES Bespoke Jc5000 Jaw Crusher Brochure

HeavyDuty Frame & Welded Stress Relief | Technical Basis: Finite Element Analysis (FEA) optimized steel fabrication with postweld heat treatment | Operational Benefit: Eliminates frame fatigue cracking under cyclical loads; ensures longterm structural integrity in 24/7 operations | ROI Impact: Extends service life by decades; prevents catastrophic frame failure requiring total unit replacement.

Hydraulic Toggle & Adjustment System | Technical Basis: Integrated hydraulic ram for toggle tensioning and automatic clearing | Operational Benefit: Allows quick adjustment of CSS under load and automatically releases tramp metal, resetting itself without manual intervention | ROI Impact: Reduces unplanned downtime from tramp events by up to 80%; enables precise product control without stopping.

Quarry+ Jaw Die Design | Technical Basis: Optimized tooth profile and thicker manganese sections based on cavity dynamics simulation | Operational Benefit: Increases wear life by promoting interparticle crushing; reduces frequency of die rotation/replacement cycles | ROI Impact: Lowers costperton for wear parts; extends campaign life between maintenance stops by an average of 35%.

Direct Drive via VBelts & TEFC Motor | Technical Basis: Hightorque motor connected via multiple Vbelts to flywheel shaft | Operational Benefit: Provides smooth power transmission, absorbs load shocks better than directcoupled drives; standard TEFC motor suits harsh environments | ROI Impact: Reduces stress on drive components; lowers maintenance complexity; improves overall electrical efficiency.

Integrated PreFabricated Installation System | Technical Basis: Unit supplied with preengineered base frame, motor subframe, and alignment aids | Operational Benefit: Dramatically reduces field installation time and ensures perfect alignment for optimal vibrationfree operation | ROI Impact: Cuts commissioning time by up to 50%, accelerating timetoproduction.

4. COMPETITIVE ADVANTAGES Bespoke Jc5000 Jaw Crusher Brochure

_Availability based on comparable duty in hard rock applications._

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1600mm (51" x 63")
Maximum Feed Size: Up to 1100mm (43")
Closed Side Setting Range: 150mm 300mm (6" 12")
Capacity Range: 750 1500 metric tons per hour (varies with material density, feed gradation, and CSS)
Drive Power Requirement: 200 kW / 250 HP electric motor (TEFC)
Total Weight (Crusher Only): Approximately 86,000 kg
Key Material Specifications:
Frame: Fabricated steel plate (SAE 1020), stressrelieved.
Swing Jaw/Fixed Jaw: Highstrength cast steel.
Jaw Dies: Premium Manganese Steel (14%18%).
Eccentric Shaft: Forged alloy steel EN24/34CrNiMo6+.
Operating Temperature Range: 20°C to +45°C (4°F to +113°F)
Foundational Requirements: Detailed civil drawings provided; requires substantial mass concrete foundation.

6. APPLICATION SCENARIOS

Hard Rock Gold Mine – Primary Ore Reduction

Challenge: A West African gold mine faced excessive downtime from weekly jaw die rotations and monthly maintenance stops on their aging primary crusher. Unpredictable wear was causing throughput fluctuations.
Solution: Installation of a Bespoke JC5000 jaw crusher with Quarry+ dies and hydraulic toggle system.
Results: Achieved a consistent campaign life of 6 weeks between die rotations. The hydraulic system cleared two major tramp metal events without stoppage. Annual availability increased from 86% to 93%, contributing to an estimated 18,000 additional tons processed annually.

Granite Quarry – Aggregate Base Production

Challenge: A large quarry supplying road base material needed more consistent product gradation to meet strict DOT specifications without secondary recrush. Their existing crusher produced excessive flaky material.
Solution: Implementation of the JC5000 with its optimized crushing chamber geometry and easyadjust hydraulic CSS control.
Results:
CSS adjustments under load allowed operators to finetune output in minutes versus hours. The improved nip angle produced a more cubical product at the primary stage,
reducing load on secondary cone crushers by 15%. Overall plant yield of inspec material increased by 8%.

7. COMMERCIAL CONSIDERATIONS

The Bespoke JC5000 is offered as a capital investment designed for longterm operational payback.

Base Equipment Price Tier: Includes crusher assembly,
hydraulic toggle adjustment system,
standard jaw dies,
drive sheaves,
and documentation pack.

Optional Features & Upgrades
– Automated Greasing System
– Wear Monitoring Kit (laser profile)
– Special Alloy Jaw Dies for highly abrasive feeds
– Custom SkidMounting for semimobile applications

Service Packages:
1. Commissioning Support Package
2.Planned Maintenance Agreement
3.FullService Contract

Financing Options:
Available through our partners including equipment leasing,
operational leasetoown structures,
and project financing tailored for major capital expenditure

8.FAQ

Q1.Is the JC5000 compatible with my existing plant feed system( apron feeder/vibrating grizzly)?
A1.The JC5000 requires proper feed regulation but is designed to interface with standard industrial feeding equipment.Critical dimensions are provided early in the specification process

Q2.What is the expected operational costperton for wear parts?
A2.Costperton varies based on material abrasiveness.In comparable granite applications,the Quarry+ die design has demonstrated costs 2030% lower than previous generation jaws.Field data is available upon request

Q3.How does the hydraulic toggle system affect routine maintenance?
A3.It simplifies it.The system eliminates mechanical springs/shims reducing inspection points.Lubrication requirements are centralized.Routine tasks focus primarily on die condition monitoring

Q4.What training is provided for our maintenance crew?
A4.A comprehensive twoday onsite training program covers safe operation daily inspections routine maintenance procedures basic troubleshooting specific to this machine's systems

Q5.Are there financing options that align payback periods with projected efficiency gains?
A5 Yes.We offer structured finance solutions where repayment schedules can be modeled against typical efficiency gains(energy savings extended wear life increased throughput)

Q6.Can you provide sitespecific foundation drawings?
A6.Upon order confirmation we provide detailed certified foundation drawings including all loading data anchor bolt locations necessary for your civil engineering team

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