1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mining profit margins? For plant managers and procurement specialists, the primary crushing stage is often a source of significant bottlenecks and maintenance headaches. Common challenges include:
Excessive Wear Part Costs: Frequent replacement of jaw dies due to improper kinematics or material quality, directly impacting your costperton.
Unscheduled Downtime: Premature failures of critical components like bearings or frames, halting your entire processing line.
Inconsistent Product Gradation: Fluctuations in CSS (Closed Side Setting) from frame flex or wear lead to offspec product, causing recrush cycles and wasted energy.
High Energy Consumption: Inefficient crushing chambers and drive systems that draw excessive power without maximizing throughput.

How do you select a primary crusher that delivers predictable performance, lowers your total cost of ownership, and provides the robustness required for 24/7 operation? The solution requires an engineered focus on durability, efficiency, and serviceability.

2. PRODUCT OVERVIEW

The Custom Jc5000 is a heavyduty, singletoggle jaw crusher designed for highcapacity primary crushing in demanding quarrying, mining, and demolition recycling applications. Engineered for maximum reliability and reduced operational expense, it processes hard rock, ores, and concrete with consistent performance.

Operational Workflow:
1. Feed Intake: Large feed material (up to 1300mm) is delivered via dump truck or loader into the vibrating grizzly feeder (optional) or directly into the deep crushing chamber.
2. Crushing Action: The aggressive elliptical jaw motion ensures high reduction ratios, effectively nipping and crushing material to the required size on the first pass.
3. Discharge: Crushed product exits through the discharge opening at the bottom, with CSS hydraulically adjustable for precise control over final product size.

Application Scope & Limitations:
Scope: Ideal for primary reduction of abrasive granite, basalt, iron ore, and recycled concrete. Suitable for both stationary plants and large mobile tracked setups.
Limitations: Not designed for sticky, clayrich materials without prescreening. Maximum capacity is contingent on feed material characteristics and desired product size.

3. CORE FEATURES

HeavyDuty Fabricated Frame | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading | ROI Impact: Extended structural life reduces risk of catastrophic failure and associated replacement costs.

Hydrostatic Drive & PLC Control | Technical Basis: Direct hydraulic drive with variable speed control via programmable logic controller | Operational Benefit: Enables soft starts, reversible operation to clear blockages, and optimized power use based on load | ROI Impact: Lower inrush current demands protect electrical infrastructure; reversible function minimizes downtime from stalls.

WedgeLock Jaw Die Retention System | Technical Basis: Mechanically locked wedges secure jaw dies without backing material | Operational Benefit: Faster, safer die changes requiring only standard tools; eliminates resin curing time | ROI Impact: Reduces liner changeout time by up to 50%, increasing plant availability.

Spherical Roller Bearing Assembly | Technical Basis: Selfaligning roller bearings housed in precisionmachined cartridges | Operational Benefit: Accommodates shaft deflection under load; runs cooler than standard bearings | ROI Impact: Documented bearing life extension of 3040% under equivalent loads reduces part change frequency.

Hydraulic Toggle Adjustment System | Technical Basis: Integrated hydraulic ram for setting adjustment and overload relief | Operational Benefit: Allows remote CSS adjustment under load; automatically resets after tramp metal events | ROI Impact: Maintains product spec consistency; protects crusher from uncrushables without manual intervention.

Aggressive Crushing Chamber Geometry | Technical Basis: Deep symmetrical chamber with steep nip angle design | Operational Benefit: Promotes accelerated material breakdown and reduces slabby output | ROI Impact: Increases throughput rates by 1015% over conventional designs with similar feed openings.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | Custom Jc5000 Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Life (Mn18/22 Jaw Dies)| ~120,000 MT granite (CSS 150mm)| ~160,000 MT granite (CSS 150mm)| +33% longer life |
| Energy Consumption| Fixed speed motor (~355 kW average draw)| Hydrostatic drive with loadsensing (~310 kW average draw)| Up to 13% lower power draw |
| Maintenance Downtime (Annual)| Estimated 80100 hours for liner/bearing service| Estimated 5060 hours due to accessible design| ~40% reduction in service time |
| Availability (Uptime %)| Industry target of ~9294%| Field data indicates consistent >96%| +24 percentage points |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm (51" x 40")
Maximum Feed Size: Up to 1100mm edge length
Capacity Range: 450 750 Mtph (dependent on material & CSS)
Drive System: Hydrostatic drive with PLCcontrolled electric motor
Power Requirement: Standard package rated at 355 kW / Tier III / Stage V compliant
Main Frame Construction: Welded steel plate with reinforced stress zones; stressrelieved
Jaw Die Material Options: Standard Mn18%, Premium Mn22%, or Martensitic Iron
Machine Weight (Approx.): ~78,000 kg
Operating Temperature Range: 25°C to +45°C (13°F to +113°F)
Dust Suppression: Provision for water spray nozzles at inlet/outlet

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing Station Upgrade

Challenge: A large granite quarry faced monthly jaw die changes on their existing crusher due to abrasive wear. This resulted in over 16 hours of planned downtime monthly plus high consumable costs.
Solution: Implementation of a Custom Jc5000 Jaw Crusher equipped with premium martensitic iron jaw dies.
Results: Wear part intervals extended to six weeks. Combined with faster changeout times from the wedgelock system total annual crusher downtime was reduced by approximately 180 hours—a direct increase in production time—and consumable costs per ton fell by an estimated 28%.

Iron Ore Processing Plant Expansion

Challenge: A new processing line required a primary crusher capable of handling lump ore up to ~1m³ while operating reliably in a highdust environment with minimal thermal issues.
Solution: A Custom Jc5000 was selected for its sealed spherical roller bearing cartridge design integrated dust sealing system.
Results: The plant achieved design throughput within two weeks of commissioning Field data shows bearing temperatures consistently within safe operating parameters despite ambient conditions exceeding 40°C Crusher availability has been maintained at 97% over the first year

Major Infrastructure Demolition Recycling

Challenge A contractor needed a mobile primary solution capable of processing heavily reinforced concrete slabs while being easily transportable between urban sites Solution A trackmounted Custom Jc5000 plant featuring the hydraulic reverse crush function was deployed Results The hydrostatic drive allowed precise control for varying feed materials while the reversible action cleared steel jams instantly This enabled processing rates exceeding 550 tph of mixed demolition debris meeting tight project timelines

COMMERCIAL CONSIDERATIONS FOR THE CUSTOM JC5000 JAW CRUSHER

Equipment pricing is structured around core configuration requirements:

Tier I – Base Unit Includes fabricated frame standard jaw dies hydrostatic drive basic PLC controls electrical motor starter

Tier II – Production Ready Package Adds automated grease lubrication system integrated water spray dust suppression premium jaw die option onboard maintenance tools

Tier III – Turnkey Skid Package Comprises full base skid structure including walkways handrails discharge conveyor prerun cabling readyforhookup

Optional Features:
• Radio remote control / automation interface kit
• Belt scale integration package
• Specialized wear liners for specific abrasives
• Cold climate package heaters insulated covers

Service Packages:
• Commissioning & Operator Training Onsite startup supervision comprehensive training program documentation review

• Preventive Maintenance Plans Scheduled inspections parts kits priority technical support fixed annual cost structure

• Performance Guarantee Plans Extended warranty covering uptime commitments subject to agreed operating parameters

Financing Options Available through partners include equipment leasing longterm rentaltoown agreements projectspecific financing solutions tailored capital expenditure planning assistance provided upon request

FAQ CUSTOM JC5000 JAW CRUSHER IMPLEMENTATION

Q What are my foundation requirements?
A Detailed civil drawings are provided specifying loadings anchor bolt locations Due its robust base frame foundation demands are typically less complex than older designs reducing civil works cost

Q How does this integrate into my existing plant?
A The crushers PLC can communicate via standard industrial protocols Modbus Ethernet/IP Conveyor interlock signals can be easily integrated Electrical connection requires standard highvoltage supply specifications detailed in our installation manual

Q What is your delivery lead time?
A For standard configurations lead time is typically weeks following order confirmation Custom configurations may require additional engineering time which will be confirmed during project quotation phase We provide regular milestone updates throughout manufacturing process

Q Can you provide performance guarantees?
A Yes we offer guaranteed capacity wear rates based on certified feed material analysis These form part commercial agreement ensuring equipment meets your specific production targets before purchase finalized