1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y la disponibilidad impredecible están erosionando la rentabilidad de su circuito de trituración primario?? Para gerentes de planta y contratistas de ingeniería, La trituradora giratoria es un activo crítico donde las fallas tienen consecuencias exponenciales.. Los desafíos comunes incluyen:
Tiempo de inactividad no programado: Bearing failures or mainshaft issues can halt entire processing lines for days, costing hundreds of thousands in lost production.
Altos costos de mantenimiento: Frecuente, laborintensive liner changes and component wear directly impact maintenance budgets and manpower allocation.
Rendimiento inconsistente: Poor feed distribution or worn crushing surfaces lead to product gradation fluctuations, downstream bottlenecks, and reduced overall plant efficiency.
Ineficiencia energética: Older or poorly optimized designs consume excessive power per ton of processed material, a fixed cost that directly affects operating margins.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The answer lies in a purposeengineered gyratory crusher from a dedicated private label manufacturer focused on R&Ddriven performance.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This product is a highcapacity primary gyratory crusher, engineered for private label partners who require robust, applicationspecific solutions for largescale mining and aggregate operations. Its design focuses on delivering maximum availability and optimal reduction ratios for hard, abrasive ores and rock.

Flujo de trabajo operativo:
1. Aceptación de alimentación: Oversize material from haul trucks or loaders is directed into the steepsided feed hopper.
2. Acción aplastante: The hydraulically adjusted mainshaft assembly gyrates within the concave liners, applying compressive force to reduce material size.
3. Descargar: Crushed product exits through the discharge opening at the bottom of the crushing chamber, with size controlled by the hydraulic setting adjustment system.
4. Manejo de materiales: The product is conveyed to downstream secondary crushing or screening circuits.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal para alto tonelaje (2,000+ TPH) primary crushing applications in metal ore mines (cobre, hierro, oro), large quarries producing aggregate, and major construction projects requiring onsite primary reduction.
Limitaciones: No apto para operaciones de bajo tonelaje. (<500 TPH), recycling applications with high tramp metal content without extensive protection systems, or portable/mobile plant installations due to size and weight.

3. CARACTERÍSTICAS PRINCIPALES

Perfil cóncavo patentado | Base técnica: Optimized crushing chamber geometry based on discrete element modeling (DEM) | Beneficio operativo: Delivers a consistent chokefed crushing action for uniform wear and stable product gradation | Impacto del retorno de la inversión: Extends liner life by an average of 1520%, reducing liner cost per ton and changeout frequency

Integrated Smart Bearing System | Base técnica: Multisensor monitoring of bearing temperature, vibración, and lubrication pressure | Beneficio operativo: Provides early warning diagnostics to prevent catastrophic bearing failure | Impacto del retorno de la inversión: Eliminates unplanned downtime events related to bearing issues, protecting millions in potential production losses

Hydraulic Setting & Protección contra sobrecarga | Base técnica: Dualfunction hydraulic cylinder for precise CSS adjustment and automatic relief under uncrushable material | Beneficio operativo: Allows operators to adjust product size remotely and protects the crusher from mechanical damage | Impacto del retorno de la inversión: Reduces setting time by 70% compared to manual systems and prevents costly repairs from tramp steel events

Filosofía de diseño TopService | Base técnica: All routine service tasks (cambios de revestimiento, spider arm refurbishment) accessible from above | Beneficio operativo: Eliminates the need for personnel to work beneath suspended components or dismantle the crusher structure | Impacto del retorno de la inversión: Reduce el tiempo de inactividad por mantenimiento programado hasta en 50%, enhancing plant availability

Transmisión directa & Torque Limiter System | Base técnica: Lowspeed synchronous motor coupled via an air clutch with torque limiter | Beneficio operativo: Provides smooth startup under load capability and protects drive train from shock loads | Impacto del retorno de la inversión: Reduces electrical stress during startup by 60% versus VFDonly solutions, lowering peak demand charges

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Punto de referencia estándar de la industria | This Gyratory Crusher Solution | Ventaja documentada |
| : | : | : | : |
| Disponibilidad mecánica (Objetivo) | 92 94% | >96% (Contractual Target) | +24 puntos porcentuales |
| Vida del revestimiento (mineral abrasivo) | ~6 meses (Varies) | 78 Meses (Average Field Data)| +1520% Mejora |
| Consumo de energía específico (kWh/t) ~0.8 1.2 kWh/t ~0.7 0.9 kWh/t ~1015% Improvement |
| Tiempo de ajuste de CSS <4 Horas 75% Más rápido |
| Costo total de propiedad (5Proyección del año)| Baseline Model Averages +1218% Menor costo total de propiedad |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 2,000 a más 10,000 toneladas métricas por hora (tph), depending on model size and feed material.
Potencia del motor: Unidades estándar de 450 kW hasta 1 MW+; engineered to client specifications.
Apertura de alimentación: Tamaños de apertura desde 1,300 mm a 1,800 mm available.
Especificaciones de materiales:
Marco principal & Head Center: Highstrength cast steel alloy.
Cóncavo & Mantle Liners: Aleaciones de acero al manganeso.; optional premium alloys for specific abrasion/impact conditions available.
Eje principal: Forged alloy steel with precision machining.
Dimensiones físicas & Peso: Significant footprint; exact dimensions provided per model. Approximate installed weights range from 350 toneladas a más 800 montones.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 40°C a +50°C con sistemas de lubricación adecuados; estándar de sellado de polvo.

6. ESCENARIOS DE APLICACIÓN

Ampliación de la mina de cobre

Challenge A Tier1 copper operation needed to increase primary circuit throughput by 25% without expanding their truck fleet or dump pocket footprint. Their existing crusher was a bottleneck with frequent linerrelated downtime.

Solution Implementation of our largestcapacity gyratory crusher model featuring the patented concave profile for higher reduction ratio in a single pass.

Resultados El rendimiento aumentó en 28%. Liner life improved from an average of approximately five months to sixandahalf months under identical ore conditions. Annual production targets were met three weeks ahead of schedule following commissioning.

Granite Quarry Primary Circuit Upgrade

Challenge A major aggregate producer faced volatile energy costs and high maintenance expenses on their aging primary crusher. Product consistency was also an issue affecting their premium product lines.

Solution A midrange gyratory crusher was selected with a focus on energy efficiency via direct drive optimization and superior chamber geometry.

Results Specific energy consumption decreased by an average of approximately twelve percent yearoveryear despite increased operating hours.The consistent gradation reduced recirculating load in secondary circuits by nearly eighteen percent.The quarry reported meeting tighter specification bands more reliably for key customer contracts.

7. CONSIDERACIONES COMERCIALES

Our private label manufacturing model provides flexible commercial pathways tailored for OEMs and largescale endusers:

Niveles de precios: Structured around core model size (apertura de alimentación), drive power rating,and level of standard automation.Control system integration is offered as either basic local control or full PLC/SCADA interface packages.

Características opcionales & Actualizaciones: Key options include advanced predictive maintenance sensor suites,kits de anillos de supresión de polvo,material level monitoring systems,and proprietary wearresistant alloy packages for liners.

Paquetes de servicios: Available service agreements range from basic technical documentation support through comprehensive multiyear performance contracts covering planned maintenance,inspecciones,and guaranteed parts availability with defined response times.

Opciones de financiación: We work with established financial partners ableto structure leasing arrangements,tailored payment plans aligned with project milestones,and other financing solutions upon request.This facilitates capital budget planningfor our clients' projects.

8.Preguntas frecuentes

q:What levelof engineering supportis provided duringthe integrationof thisgyratorycrusherintoan existingplantlayout?
A OurR&Dandapplicationengineeringteamsworkdirectlywithyourprojectengineersto reviewfoundationdesignsfeedanddischargearrangementsandinterfacingwithexistingconveyorsystemsWe providecomprehensivelayoutdrawingsforcesandloaddatato ensureproperintegration

q:Canyourcrushersbeconfiguredtooperatewithautomationsystemssuppliedbyothervendors?
A YesThecorecrushercontrolsystemisdesignedwithstandardindustrialcommunicationprotocols(egOPCUAProfibusEthernet/IP)allowingforseamlessdataintegrationintoplantwideprocesscontrolandmonitoringsystems

q:Whatisthetypicalleadtimefromordertocommissioningforastandardmodel?
A Leadtimesvarybymodelsizeandcustomizationbutgenerallyrangefrom12to18monthsforcompletecrushersupplyincludingengineeringmanufacturingfactorytestinganddeliverySchedulesareconfirmeduponprojectkickoff

q:Aretheredocumentedcasesofretrofittingyourcrushingchambertechnologyintoexistinggyratorycrushersfromothermanufacturers?
A WhileourprimaryfocusisnewunitswehaveexecutedseveralsuccessfulmodernizationprojectsforcompatiblelegacycrushersTheseinvolvereplacingkeywearcomponentsandsometimeshydraulicsystemstodeliverperformanceimprovementsAcasestudyreviewcanbe provideduponrequest

q:Whatdefinesthe"Costo total de propiedad"advantageinyourcomparisons?
A OurTCOanalysisovera5yearperiodaccountsforinitialcapitalcostenergyconsumptionprojectedwearpartslifeandreplacementcostsscheduledmaintenancelaborhoursandexpectedavailabilitylossesFielddatafromsimilarenvironmentsformsthebasisfortheseprojections

q:Doyouoffertestcrushingofcustomermaterialsamplespriorto purchase?
A YesWeoperateapilotscalecrushingfacilityandcanperformcomprehensivematerialtestworkincludingabrasivenessandcompressionstrengthanalysisto validatecapacitymodelingandliner liferecommendationsThisdataisincludedinourtechnicalproposal

q:Whatarethestandardwarrantytermsforthemainmechanicalcomponents?
A Themainstructuralcomponents(mainframeheadcenter)mainshaftassemblyandbearingscarryastandardwarrantyof24monthsfromcommissioningor26monthsfromshipmentwhicheveroccurfirstsubjecttocorrectinstallationoperationasperourmanuals