Certified Stone Crusher Machine | HighCapacity Primary & Secondary Crushing Solutions

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 and secondary crushing are quantifiable:
Unscheduled Downtime: Bearing failures or component wear can halt your entire processing line, costing thousands per hour in lost production and labor.
Inconsistent Output & Product Contamination: Fluctuations in feed size or hardness lead to offspec aggregate, increasing waste and causing rejections from highvalue contracts.
Excessive Energy Consumption: Older or inefficient crushing chambers and drives consume disproportionate power, directly impacting your costperton metric.
High Maintenance Complexity: Lengthy, specialized procedures for wear part replacement or adjustment keep your team from proactive tasks.

Is your current crushing solution a recurring cost center rather than a reliable asset? The following certified stone crusher machine addresses these operational realities with engineered precision.

2. PRODUCT OVERVIEW

This certified stone crusher machine is a heavyduty, jaw and cone crusher series designed for highvolume stationary crushing plants. Its design focuses on transforming blasted quarry rock or large river stone into consistent, specification aggregates for construction, road base, and concrete production.

Operational Workflow:
1. Primary Reduction (Jaw Crusher): Large feed material (up to 1200mm) is compressed between a fixed and a reciprocating jaw plate, achieving the first stage of size reduction.
2. Material Transfer: Crushed discharge from the primary unit is conveyed to a secondary screening stage.
3. Secondary/ Tertiary Crushing (Cone Crusher): Oversize material from screens is directed to the cone crusher for further reduction in a compressive crushing chamber, producing precisely shaped end products.
4. Final Sizing: Correctly sized aggregate is routed to final product stockpiles.

Application Scope & Limitations:
Scope: Ideal for hard rock (granite, basalt), abrasive materials, and recycled concrete. Suited for stationary plant installation with integrated material handling systems.
Limitations: Not designed as a mobile trackmounted unit. Maximum feed size and capacity are fixed by model selection; processing of clayheavy or highly moist feed may require prescreening.

3. CORE FEATURES

Patented Crushing Chamber Geometry | Technical Basis: Computeroptimized kinematics and cavity profile | Operational Benefit: Delivers a consistent crush curve, reducing flaky or elongated particles in final aggregate | ROI Impact: Improves product marketability and reduces waste by up to 15%, based on field data.

HeavyDuty Integrated Main Frame | Technical Basis: Singlepiece, highintegrity steel casting with reinforced ribbing | Operational Benefit: Eliminates frame fatigue and misalignment under cyclical loading, ensuring longterm bearing alignment | ROI Impact: Extends structural service life beyond industry norms, protecting your capital investment.

Automated Wear Compensation & Setting Regulation | Technical Basis: Hydraulic adjustment system with PLC interface | Operational Benefit: Allows operators to adjust crusher settings in minutes without manual shims, maintaining product gradation as wear parts age | ROI Impact: Reduces adjustment downtime by approximately 70% and maintains consistent output quality.

DualPurpose Hydraulic Clearing & Overload Protection | Technical Basis: Integrated hydraulic cylinders serve both for clearing tramp metal blockages and resetting the machine after an overload event | Operational Benefit: Clears a stalled cavity in under two minutes, protecting the drivetrain from catastrophic damage | ROI Impact: Prevents costly secondary damage to eccentric assemblies and shafts, minimizing major repair incidents.

Centralized Greasing & Condition Monitoring Points | Technical Basis: Manifold system linking all major bearing points to a single greasing station with sensor ports | Operational Benefit: Enables safe, rapid routine maintenance and facilitates oil sample collection for predictive analysis | ROI Impact: Lowers scheduled maintenance time by 30% and enables proactive component replacement planning.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Certified Stone Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime)| 9294% | 96%+ | ~4% increase in productive hours |
| Tonnage per kWh| Sitedependent baseline +15% improvement target based on chamber efficiency metrics |
| Wear Part Life (Mn18/22)| Varies with abrasiveness +2035% longer life demonstrated in comparative field trials |
| Mean Time To Repair (MTTR)| 812 hours for major adjustments 50% reduction in critical downtime |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 200 1,800 tonnes per hour (model dependent).
Power Requirements: 90 450 kW electric motor drive; standard supply 50/60Hz, customizable voltage.
Feed Opening (Jaw): Ranges from 900mm x 600mm up to 1500mm x 1300mm.
Max Feed Size: Up to 8085% of crusher inlet dimensions.
Material Specifications: Highgrade alloy steel main frame; Manganese steel wear liners (Mn18Cr2/Mn22Cr2 optional); Forged alloy steel eccentric shaft.
Physical Dimensions (Sample Model): Approx. L10m x W4m x H5m (including drive guards).
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dustprotected bearings; optional heating/cooling systems available.

6. APPLICATION SCENARIOS

Granite Quarry Operation – Southeast Asia

Challenge: A large granite quarry faced frequent liner fractures in their secondary crushers due to uncrushable material ingress, causing weekly stoppages averaging 6 hours each.
Solution: Implementation of our certified stone crusher with its dualpurpose hydraulic overload protection system.
Results: In the first year of operation, zero downtime events were recorded from tramp metal or overloads. Unplanned stoppages related to the secondary circuit fell by over 95%, contributing to an estimated additional 12,000 tonnes of annual output.

Urban Recycled Aggregate Producer – Europe

Challenge: Processing demolished concrete with inconsistent reinforcement levels led to poor product shape and high wear costs on existing equipment.
Solution: Installation of a primary jaw crusher model equipped with automated wear compensation and a heavyduty clearing system.
Results: Product cubicity improved by over 22%, meeting strict local authority specifications for road base. Wear part consumption decreased by an average of 28%, significantly lowering costpertonne for recycled material.

7. COMMERCIAL CONSIDERATIONS

Our certified stone crushers are offered under clear commercial terms designed for capital project planning:

Pricing Tiers: Structured across three primary capacity classes—HighCapacity Primary (>1000tph), Standard Stationary Plant (3001000tph), and Compact Configuration (<300tph). Detailed quotations are provided upon review of your specific feed material analysis and output requirements.
Optional Features: Remote monitoring telematics package; automatic lubrication systems; special alloy wear liner upgrades; dust suppression sealing kits; custom discharge conveyor fittings.
Service Packages:
Platinum Support: Includes scheduled inspections, parts discounting priority access to field service engineers
Gold Support: Covers annual inspection plus discounted parts
Basic Warranty: Standard manufacturer’s warranty covering defects in materials/workmanship
Financing Options Available through partnered financial institutions including equipment leasing capital expenditure loans

FAQ

What type of drive system is used?
Machines are equipped with direct Vbelt drives from TEFC electric motors This configuration provides proven reliability efficient power transmission allowing for some load variation

Can this crusher replace our existing model without plant redesign?
Dimensional drawings foundation loadings are provided for evaluation While frames are robust designs often require new foundations feed arrangements due optimized geometry We provide full installation documentation

How does automated wear compensation affect product consistency?
The hydraulic setting adjustment system allows operators maintain closed side setting CSS within +/3mm tolerance as liners wear This translates stable product gradation throughout liner life reducing need constant manual checks

What is included standard warranty?
Standard coverage includes months operation or hours runtime whichever comes first covering major components frame eccentric assembly against defects Optional extended warranties available

Do you provide sample testing pilot studies?
Yes we can arrange testing representative samples our facility provide detailed report predicted performance wear rates based actual material analysis

What lead time expected delivery?
Lead times vary capacity model current production schedule Typically range weeks standard configurations Custom configurations may require additional time

Are spare parts readily available global distribution network?
We maintain centralized regional warehouses critical wearing mechanical parts ensuring availability Genuine OEM parts recommended guarantee performance longevity