1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges in primary crushing often stem from the crusher itself. Common pain points include: excessive wear part consumption due to nonoptimal chamber design, leading to material costs increasing by 1525% annually; unplanned stoppages from tramp metal events or uncrushables, resulting in 40+ hours of lost production per year; and inconsistent product gradation that forces secondary and tertiary crushers to work inefficiently, raising power costs per ton. Furthermore, maintenance complexity can require 2030% longer service intervals, increasing labor overhead. Are you evaluating how a primary jaw crusher can deliver not just raw power, but measurable reliability and costperton efficiency to stabilize your entire processing line?

2. PRODUCT OVERVIEW

The Bespoke TJ900 Series Primary Jaw Crusher is a heavyduty, singletoggle machine engineered for the first stage of size reduction in quarrying, mining, and demolition recycling applications. Its operational workflow is designed for robustness: (1) Material is fed into a deep, nonchoking crushing chamber; (2) An aggressively angled nip zone and high inertia flywheels facilitate forceful compression crushing; (3) A fixed jaw die configuration ensures consistent feed opening geometry; (4) The hydraulic toggle relief system automatically resets after clearing a cavity; (5) Crushed material discharges at a preset CSS with minimal slabby product.

Application Scope: Ideal for processing hard abrasive materials like granite, basalt, and recycled concrete. Limitations: Not designed for sticky, plastic materials or as a standalone solution for producing specification aggregate without downstream screening and secondary crushing.

3. CORE FEATURES

Monobloc HighStrength Steel Frame | Technical Basis: Finite Element Analysis (FEA)optimized stress distribution | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading, ensures lifetime alignment of bearing housings | ROI Impact: Reduces risk of catastrophic structural failure, protecting capital investment over a 20+ year service life.

Hydraulic Toggle & Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace mechanical toggle plates | Operational Benefit: Enables remote CSS adjustment under load and provides automatic overload protection against tramp metal | ROI Impact: Cuts adjustment downtime by 80% and prevents costly damage to pitman and bearings from uncrushable events.

QuarryGrade Spherical Roller Bearings | Technical Basis: Larger diameter bearings with automated grease lubrication circuits | Operational Benefit: Sustains higher radial and axial loads at lower operational temperatures | ROI Impact: Extends bearing service life by an average of 35%, directly lowering parts inventory costs.

Asymmetric Jaw Die Design | Technical Basis: Computeraided kinematics optimizing stroke profile at both top and bottom of chamber | Operational Benefit: Produces more uniform product gradation with increased throughput per stroke cycle | ROI Impact: Improves overall plant throughput by 812% without increasing primary crusher horsepower.

Integrated PreScreening Grizzly Feeder Option | Technical Basis: Bolton vibrating grizzly section with adjustable bypass chute | Operational Benefit: Removes fines and subCSS material prior to crushing chamber, reducing wear and power consumption | ROI Impact: Lowers jaw die wear rates by up to 20% and decreases fuel/power use per ton of finished product.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Bespoke TJ900 Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Part Life (Mn/Ton) | 0.8 1.2 Mn/Ton | 1.4 1.6 Mn/Ton | +40% |
| Availability / Uptime (%)| ~92% |>96% (documented) |>4 Percentage Points |
| Power Consumption (kWh/Ton)| 0.9 1.1 kWh/Ton|0.75 0.85 kWh/Ton |18% |
| CSS Adjustment Time (Minutes)|45 60 minutes|<10 minutes |85% |
| Noise Emission at 10m (dB(A))|105 110 dB(A)|<98 dB(A) |7 dB(A) |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Up to 750 MTPH, dependent on feed material and closed side setting (CSS).
Feed Opening: 1400mm x 900mm.
Power Requirements: 132 kW Electric Motor or Tier IV Final / EU Stage V compliant diesel drive.
Material Specifications: Main frame fabricated from ST52 steel; jaw dies available in AR400 or manganese steel (18%); shaft manufactured from forged EN24 alloy steel.
Physical Dimensions: Approx. Length: 7m x Width 3m x Height 3m.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C.

6. APPLICATION SCENARIOS

Granite Quarrying Operation in Scotland

Challenge: A major quarry faced premature failure of jaw dies every 120k tons due to highly abrasive feed, coupled with weekly downtime for manual CSS adjustments.
Solution: Implementation of the Bespoke TJ900 Jaw Crusher with asymmetric manganese dies and the hydraulic toggle/adjustment system.
Results: Wear part life extended to 190k tons (+58%). Remote CSS adjustments reduced monthly downtime by 6 hours (85%). Overall plant availability increased by 4%.

Urban Demolition Recycling Contractor

Challenge: Processing mixed demolition debris led to frequent tramp metal incidents (rebar, steel beams), causing regular shutdowns and repair bills exceeding £15k annually.
Solution: Deployment of the TJ900 Jaw Crusher equipped with an overband magnet on the feed conveyor and the integrated hydraulic overload protection.
Results: The system automatically cleared over 95% of tramp events without stopping production or causing damage. Annual unscheduled repair costs fell below £2k.

7. COMMERCIAL CONSIDERATIONS

The Bespoke TJ900 Series is offered in three primary configurations:
1. Base Unit Tier: Core crusher with standard electric drive motor starter package.
2. PlantReady Tier: Includes integrated motor mount/vbelts, hydraulic power unit for toggle/adjustment walkway platforms safety guards.
3. Modular System Tier: Full skidmounted solution incorporating prescreening grizzly feeder discharge conveyor walkways.

Optional features include dust suppression systems automated lubrication monitoring wear part sensor packages various liner profiles

Service packages range from basic commissioning support up to comprehensive annual maintenance contracts with guaranteed parts availability within 48 hours

Flexible financing options are available including equipment leasing operating lease agreements tailored to project cash flow

8.FAQ

Q What is the compatibility of the TJ900 with my existing primary feed conveyor?
A The crusher features a standard flanged feed hopper interface Field data shows successful integration with most apron feeders vibrating grizzly feeders Conveyor height/feed rate analysis is recommended during specification

Q How does this jaw crusher impact my downstream screening efficiency?
A The asymmetric chamber design produces a more cubicle product gradation with fewer slabby particles This typically leads to improved screening efficiency on your primary screen reducing recirculating load

Q What are the commercial terms regarding warranty?
A The structural frame carries a lifetime warranty against defects Other major components like the shaft main bearings have a standard month warranty Extended warranty terms are available as part of service packages

Q What training is provided for our maintenance crew?
A Comprehensive onsite training is included covering routine maintenance procedures CSS adjustment troubleshooting hydraulic system operation Training manuals video guides are also provided

Q How long does implementation typically take from order commissioning?
A For standard configurations lead time averages weeks Delivery installation commissioning by our field engineers typically requires weeks depending on site readiness