1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando sus márgenes de ganancias agregadas o mineras?? Los desafíos clave en las operaciones de trituración primaria a menudo incluyen:

Tiempo de inactividad excesivo para mantenimiento: Los cambios frecuentes de revestimiento y los ajustes mecánicos detienen toda su línea de procesamiento, costando miles por hora en producción perdida.
Paradas no planificadas por Tramp Metal: Unseen contaminants cause significant damage to crusher internals, leading to catastrophic failure and costly repairs.
Gradación de producto inconsistente: Fluctuations in feed material or wear patterns result in offspec product, forcing recrushing and reducing plant throughput efficiency.
Altos costos operativos: Rising energy consumption per ton and the frequent replacement of highwear components directly impact your bottom line.
Rigidez para alimentar variaciones: Fixed geometry crushers struggle with changing feed sizes or material hardness, causando cuellos de botella.

Is your primary crusher a reliable asset or a constant source of concern? La solución requiere ingeniería centrada en la durabilidad, accessibility, and process stability.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The Bespoke JC5000 is a highcapacity, Trituradora de mandíbulas de palanca única diseñada para las aplicaciones de trituración primaria más exigentes en minería, cantera, and heavyduty recycling. Its robust design prioritizes continuous operation with minimal intervention.

Flujo de trabajo operativo:
1. Consumo de alimento: Material de gran tamaño de mina o cantera (hasta 1300 mm) se dirige hacia lo profundo, cámara de trituración sin asfixia.
2. Trituración compresiva: The aggressive elliptical motion of the singletoggle jaw applies intense compressive force against the fixed jaw, effectively breaking even the hardest abrasive rock.
3. Descargar & Autorización: El material triturado sale por la abertura de descarga., with a hydraulic toggle tensioning and release system providing automatic protection against uncrushables.

Ámbito de aplicación: Ideal para minería de roca dura (mineral de hierro, gold bearing ore), canteras de granito/basalto, y procesamiento de escoria. Designed as a stationary primary unit for plants targeting sustained throughputs between 750 1500 mtph depending on material and closed side setting.

Limitaciones: No diseñado para dimensionamiento de productos ultrafinos (secondary/tertiary roles) or processing of wet, materiales pegajosos sin raspado previo. Requires a solid foundation and appropriate feed system integration.

3. CARACTERÍSTICAS PRINCIPALES

Marco resistente & Alivio de tensión soldado | Base técnica: Análisis de elementos finitos (FEA) optimized steel fabrication with postweld heat treatment | Beneficio operativo: Elimina el agrietamiento por fatiga del marco bajo cargas cíclicas; ensures longterm structural integrity in 24/7 operaciones | Impacto del retorno de la inversión: Extiende la vida útil por décadas.; prevents catastrophic frame failure requiring total unit replacement.

Palanca hidráulica & Sistema de ajuste | Base técnica: Integrated hydraulic ram for toggle tensioning and automatic clearing | Beneficio operativo: Allows quick adjustment of CSS under load and automatically releases tramp metal, resetting itself without manual intervention | Impacto del retorno de la inversión: Reduces unplanned downtime from tramp events by up to 80%; enables precise product control without stopping.

Quarry+ Jaw Die Design | Base técnica: Optimized tooth profile and thicker manganese sections based on cavity dynamics simulation | Beneficio operativo: Increases wear life by promoting interparticle crushing; reduces frequency of die rotation/replacement cycles | Impacto del retorno de la inversión: Reduce el coste por piezas de desgaste.; extends campaign life between maintenance stops by an average of 35%.

Transmisión directa a través de VBelts & TEFC Motor | Base técnica: Hightorque motor connected via multiple Vbelts to flywheel shaft | Beneficio operativo: Provides smooth power transmission, absorbs load shocks better than directcoupled drives; standard TEFC motor suits harsh environments | Impacto del retorno de la inversión: Reduces stress on drive components; lowers maintenance complexity; improves overall electrical efficiency.

Integrated PreFabricated Installation System | Base técnica: Unit supplied with preengineered base frame, bastidor auxiliar del motor, and alignment aids | Beneficio operativo: Dramatically reduces field installation time and ensures perfect alignment for optimal vibrationfree operation | Impacto del retorno de la inversión: Reduce el tiempo de puesta en marcha hasta 50%, acelerando el tiempo de producción.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (trituradoras de mandibula comparables) | Bespoke JC5000 Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Use la vida (Muere la mandíbula)| Based on standard manganese profiles | Quarry+ design with thickened sections & cinemática optimizada| +3040% vida extendida |
| Tiempo de recuperación del metal atrapado| Manual clearing requiring disassembly (~48 horas) | Hydraulic toggle autoreset cycle (<10 minutos) |95% falta del tiempo |
| Disponibilidad Anual| 8590% (cambios de línea de factorización & ajustes)| Soportes de datos de campo >94% disponibilidad| +45% aumento absoluto |
| Energía por tonelada triturada| Varies significantly with setting & material| Cinemática optimizada & chamber design reduce wasteful motion| 510% mejora |
| Installation/Commissioning Period| 57 days with foundation work & alineación| Prefabricated system reduces mechanical assembly time |40% installation labor |

_Availability based on comparable duty in hard rock applications._

5. ESPECIFICACIONES TÉCNICAS

Apertura de alimentación: 1300mm x 1600mm (51" incógnita 63")
Tamaño máximo de alimentación: Hasta 1100 mm (43")
Rango de configuración del lado cerrado: 150mm 300 mm (6" 12")
Rango de capacidad: 750 1500 toneladas métricas por hora (varies with material density, gradación de alimentación, y CSS)
Requisito de potencia de accionamiento: 200 kilovatios / 250 motor electrico HP (TEFC)
Peso Total (Solo trituradora): Aproximadamente 86,000 kilos
Especificaciones clave de materiales:
Marco: Placa de acero fabricada (SAE 1020), aliviar el estrés.
Swing Jaw/Fixed Jaw: Highstrength cast steel.
Muere la mandíbula: Acero al manganeso de primera calidad (14%18%).
Eje excéntrico: Acero aleado forjado EN24/34CrNiMo6+.
Rango de temperatura de funcionamiento: 20°C a +45°C (4°F a +113°F)
Foundational Requirements: Se proporcionan dibujos civiles detallados.; requires substantial mass concrete foundation.

6. ESCENARIOS DE APLICACIÓN

Hard Rock Gold Mine – Primary Ore Reduction

Desafío: 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.
Solución: Installation of a Bespoke JC5000 jaw crusher with Quarry+ dies and hydraulic toggle system.
Resultados: Achieved a consistent campaign life of 6 weeks between die rotations. The hydraulic system cleared two major tramp metal events without stoppage. La disponibilidad anual aumentó de 86% a 93%, contribuyendo a una estimación 18,000 additional tons processed annually.

Granite Quarry – Aggregate Base Production

Desafío: 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.
Solución: Implementation of the JC5000 with its optimized crushing chamber geometry and easyadjust hydraulic CSS control.
Resultados:
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. CONSIDERACIONES COMERCIALES

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

Nivel de precios del equipo básico: Includes crusher assembly,
sistema de ajuste de palanca hidráulica,
matrices de mandíbula estándar,
drive sheaves,
and documentation pack.

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

Paquetes de servicios:
1. Paquete de soporte para la puesta en servicio
2.Acuerdo de mantenimiento planificado
3.Contrato de servicio completo

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

8.Preguntas frecuentes

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