1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando sus márgenes de producción agregada?? Para gerentes de planta y contratistas de ingeniería, the core of these challenges often originates at the primary crushing stage. Los puntos débiles comunes incluyen:

Tiempo de inactividad no programado: Las fallas mecánicas frecuentes y los cambios prolongados de componentes detienen toda su línea de procesamiento, Costando miles por hora en producción y mano de obra perdidas..
Costos de desgaste excesivos: Abrasive feed material rapidly degrades crusher liners and wear parts, leading to high consumable expenses and frequent maintenance windows.
Salida inconsistente & Forma del producto: Variable feed size or hardness results in poor yield control and substandard product gradation, reducing the value of your final aggregate.
Alto consumo de energía: Inefficient crushing chambers and drives consume excessive power, making energy one of your largest, most volatile operational costs.
Seguridad & Operational Complexity: Manual adjustment processes and inaccessible service points increase risk for your crew and extend routine maintenance time.

Is your primary crusher a constant source of reactive maintenance rather than a reliable foundation for your operation? The solution lies in selecting a machine engineered not just to crush rock, but to crush your operational costs.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: COMMERCIAL JAW CRUSHER

A commercial jaw crusher is a heavyduty, compressiontype primary crusher designed to reduce large, quarried rock (hasta 1,5 m de tamaño) into manageable feed for secondary processing. Its robust design is built for continuous, hightonnage operation in stationary plants or largescale mobile setups.

Flujo de trabajo operativo:
1. Consumo de alimento: Large dump trucks deposit runofquarry rock into the vibratory grizzly feeder, que evita el material de tamaño inferior y dirige el material de gran tamaño a la trituradora.
2. Trituración por compresión: The rock enters the fixed Vshaped chamber between a stationary jaw die and a moving jaw die. The moving jaw exerts immense mechanical pressure, fracturing the rock against the stationary surface.
3. Ajuste de configuración de descarga: The crushed material exits at the bottom opening. The size of this closedside setting (CSS) is hydraulically adjustable to precisely control final product top size without stopping the machine.
4. Transporte del producto: Crushed material is discharged onto a main conveyor belt for transport to the next stage of screening or secondary crushing.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal for primary reduction of hard abrasive materials (granito, basalto, cuarcita), mediumhard stone (caliza, arenisca), y hormigón/asfalto reciclado.
Limitaciones: No apto para pegajosos., plasticclay materials that may cause chamber packing. Maximum reduction ratios are typically 6:1 a 8:1, making secondary crushing necessary for most fine aggregate specifications.

3. CARACTERÍSTICAS PRINCIPALES

Cámara de trituración profunda & Ángulo de pellizco agresivo | Base técnica: Kinematic geometry of swing jaw motion | Beneficio operativo: Enables higher throughput capacity per stroke and effective grip on slabby material | Impacto del retorno de la inversión: Increases potential revenue output by 1015% within same machine footprint

HeavyDuty Fabricated Steel Frame with StressRelieving | Base técnica: Análisis de elementos finitos (FEA) diseño optimizado con tratamiento térmico post-soldadura | Beneficio operativo: Provides exceptional durability against shock loads and fatigue over a 20+ año de vida útil | Impacto del retorno de la inversión: Elimina el riesgo de falla catastrófica del marco.; protects longterm capital asset value

Ajuste de palanca hidráulica & Clearing System | Base técnica: Los cilindros hidráulicos de doble acción reemplazan las placas de palanca mecánicas tradicionales | Beneficio operativo: Allows remote adjustment of CSS for product control and automatic clearing of chamber blockages in minutes | Impacto del retorno de la inversión: Reduces downtime for settings changes by over 80% versus manual systems

QuikChange Jaw Die Wedge System | Base técnica: Mechanically locked wedge design for liner retention | Beneficio operativo: Permite seguridad, fast replacement of manganese jaw dies without backing material or resin pouring | Impacto del retorno de la inversión: Cuts liner changeout time by half, aumento de la disponibilidad de la planta

Volantes de alta inercia & Eje excéntrico robusto | Base técnica: Balanced rotational mass energy storage | Beneficio operativo: Smoothes peak power demands, maintains momentum under load fluctuations for consistent crushing action | Impacto del retorno de la inversión: Reduces cyclical stress on drive motor, lowering energy costs by 57% and extending component life

Supresión de polvo integrada & Water Spray System | Base técnica: Manifold with nozzles targeting feed entry and discharge points | Beneficio operativo: Effectively controls airborne particulate at source for compliance with site health regulations | Impacto del retorno de la inversión: Mitigates risk of regulatory fines and reduces housekeeping labor

Sistema de engrase automatizado centralizado | Base técnica: Programmable pump delivering precise grease volume to all key bearings | Beneficio operativo: Ensures optimal bearing lubrication without manual intervention during operation | Impacto del retorno de la inversión: Prevents premature bearing failure; Los datos de campo muestran una 40% extension in bearing service intervals.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Promedio) | Nuestra solución trituradora de mandíbulas | Ventaja (% Mejora) |
| : | : | : | : |
| Tiempo de cambio de revestimiento (Jaw Dies) | 1224 horas (mechanical/welded) | 68 horas (QuikChange Wedge) | ~50% más rápido |
| Disponibilidad (tiempo de actividad %) Encima 12 Meses| ~8590% (including adjustments/stoppages)| >94% (promedio de campo documentado) |>45 puntos porcentuales |
| Consumo de energía específico (kWh/tonelada)| Varies; línea de base = 100%| Reducción promedio documentada a ~93%| ~7% más eficiente |
| Use la vida útil de las matrices de mandíbula (Granito abrasivo)| Based on standard manganese grade| Upgraded Manganese Steel Alloy available| +1520% vida extendida |

5. ESPECIFICACIONES TÉCNICAS

Designación del modelo: JC1500HD
Apertura de alimentación: 59” x 47” (1500mm x 1200 mm)
Tamaño máximo de alimentación: Up to 47” (1200milímetros) edge length
Rango de configuración del lado cerrado: 6” – 12” (150mm – 300mm)
Rango de capacidad (@ CSS): 550 – 950 STPH (500 – 860 MTPH), dependent on material type & gradación de alimentación.
Requisito de potencia de accionamiento: Final de nivel IV / Stage V compliant dieselelectric or direct electric drive options available.
Crusher Drive Power: Arriba a 400 caballos de fuerza /300 motor electrico kilovatios.
Peso Total (Solo trituradora): Approximately ~125,000 lbs (~56,700 kg).
Especificaciones clave de materiales: Main frame fabricated highyield strength steel; Jaw dies premium manganese steel alloy; Eccentric shaft forged alloy steel; Bearings spherical roller type.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C (4°F a +113°F). Enclosed lubrication system with heating/cooling options available.

6. ESCENARIOS DE APLICACIÓN

Hard Rock Quarry Expansion Project

Challenge A granite quarry needed to increase primary circuit throughput by over 30% without expanding their plant footprint or primary feed conveyor infrastructure.
Solution Implementation of our JC1500HD jaw crusher with its deepchamber design allowed processing larger average feed size at a higher tonnage rate within existing civils.
Results Plant achieved a sustained throughput increase of 32%. The hydraulic adjustment system enabled operators to optimize CSS daily based on blast fragmentation data.

HighAbrasion Aggregate Processing

Challenge A producer processing highly abrasive trap rock faced excessive wear costs from other OEMs’ components requiring liner changes every six weeks at significant cost/downtime.
Solution Our jaw crusher was specified with optional premiumgrade manganese alloy jaws combined with an automated greasing system ensuring perfect bearing alignment under load.
Results Wear part life extended by an average of three weeks per set (+22%). Combined with faster changeout times total annual availability increased by approximately five days.

Recycled Concrete Aggregate Production

Challenge A contractor required reliable primary crushing capable handling large reinforced concrete slabs while managing tramp metal risks minimizing damage from uncrushable objects like rebar mats
Solution The JC series’ hydraulic toggle system was critical allowing automatic release clearing uncrushable objects protecting main components from overload damage
Results Zero incidents major structural damage due tramp metal over twoyear period Unplanned stoppages cleared typically under five minutes maintaining high utilization rates

7. CONSIDERACIONES COMERCIALES

Our commercial jaw crushers are offered through flexible models designed meet varying budgetary operational needs:

Niveles de precios:
Base Configuration Includes core crusher drive motor basic lubrication system standard manganese jaws
HighProduction Package Adds hydraulic adjustment/clearing automated greasing upgraded premium jaws integrated water spray
Turnkey SkidMounted Unit Crusher premounted on heavyduty skid complete with integrated feeder discharge conveyor walkways ladders electrical starters ready connect power source

Optional Features Premium alloy wear parts extended warranty coverage remote monitoring telematics package dust enclosure kits cold climate packages (30°C)

Paquetes de servicios:
Standard Warranty Comprehensive parts labor coverage first twelve months operation includes commissioning supervision
Planned Maintenance Contracts Fixed annual cost covering scheduled inspections lubrication consumables condition monitoring reporting priority technical support
FullService Agreements Covers all scheduled unscheduled maintenance including wear parts providing predictable cost per tonne crushed over multiyear term

Financing Options Available through our partners include capital lease operating lease leasetopurchase structures tailored match project cash flow timelines typical terms range three seven years

8. Preguntas frecuentes

What are my power connection options? Units can be configured direct electric drive requiring highvoltage plant connection or as dieselelectric hybrid standalone unit ideal greenfield sites lacking established grid power reducing initial infrastructure cost

How does this machine handle variations feed material hardness? The combination highinertia flywheels robust eccentric shaft allows machine absorb shock loads maintain consistent throughput even when transitioning between softer harder stone layers within same face minimizing need operator intervention adjusting feeder rates frequently

What typical lead time delivery installation? For standard configurations lead time averages sixteen twenty weeks exworks Commissioning installation supervised our engineers typically requires five ten working days depending site readiness complexity

Are wear parts readily available globally? Yes We maintain regional inventory hubs North America Europe AsiaPacific ensuring critical wear components like jaw dies available express shipment minimize any potential logisticsrelated downtime Most common parts stocked locally our dealer network

Can existing plant controls integrate new crusher’s automation systems? Yes Our control system designed communicate via standard industrial protocols Modbus TCP/IP OPC UA allowing seamless integration into your central SCADA plant management system providing operators realtime performance data alarm notifications directly familiar interface