Apuntando a la ineficiencia de la trituración primaria: The High Cost of Compromise

Are your aggregate production or mining operations constrained by the primary crushing stage? Inefficient jaw crusher performance directly impacts your entire downstream process, manifesting as:

Tiempo de inactividad excesivo para mantenimiento: Frequent liner changes and unplanned stops for blockages can consume 1520% of available operating hours, costando decenas de miles en rendimiento perdido.
Graduación impredecible del producto: Inconsistent feed opening dynamics and wear lead to poor size distribution, overworking secondary crushers and reducing final product yield.
Spiraling Operational Costs: Premature component wear, alto consumo de energía por tonelada, and high labor intensity for routine servicing erode profit margins.
Flexibilidad de alimentación limitada: Inability to handle a varied mix of feed materials (p.ej., abrasive basalt, recycled concrete with rebar, highclay ores) forces production to slow down or stop.

Is your primary crusher a reliable asset driving profitability, or a recurring source of bottleneck and expense? The solution lies in specifying equipment engineered not just to crush, sino para optimizar el coste total de propiedad.

Descripción general del producto: JC5000 HeavyDuty Jaw Crusher

The JC5000 is a robust, singletoggle jaw crusher engineered for highcapacity primary crushing in demanding quarrying, minería, y aplicaciones de reciclaje de demolición. Its design focuses on delivering consistent throughput with minimized operational intervention.

Flujo de trabajo operativo:
1. Consumo de alimento: Grande (500mm x 250mm) feed opening accepts runofmine or runofquarry material directly from haul trucks.
2. Trituración por compresión: A steep nip angle and aggressive crushing motion applies intense compressive force to fracture material against the fixed jaw plate.
3. Descargar & Autorización: The hydraulically assisted toggle system provides quick reversal of the moving jaw to clear blockages and assist in tramp metal release without stopping the crusher.
4. Transporte del producto: Crushed material exits at a consistent CSS (Configuración del lado cerrado), typically between 75mm 150mm, listo para procesamiento secundario.

Ámbito de aplicación & Limitaciones:
Ideal para: Hard rock quarries (granito, basalto), mediumscale mining operations, largescale construction waste recycling plants.
Limitaciones: Not designed for ultrafine grinding or as a standalone solution for finished aggregate. Maximum recommended feed size is 80% de la dimensión de la abertura de alimentación. Requires a stable foundation and appropriate upstream feeding equipment.

Características principales: Ingeniería para la superioridad operativa

Sistema de ajuste de palanca hidráulica | Base técnica: Integrated hydraulic cylinder replaces mechanical shims | Beneficio operativo: CSS adjustment takes minutes versus hours, performed safely from ground level | Impacto del retorno de la inversión: Reduce el tiempo de inactividad para cambios de productos hasta en 90%, increasing annual utilization.

Eje excéntrico de calidad para canteras | Base técnica: Forged from highintegrity alloy steel, soportado por rodamientos de rodillos a rótula de gran tamaño | Beneficio operativo: Sustains peak load under shock conditions; bearings run cooler with extended L10 life | Impacto del retorno de la inversión: Eliminates premature shaft failure; field data shows bearing service intervals extended by 40%.

Geometría de cámara optimizada | Base técnica: Computermodeled kinematics create an aggressive nip angle and deep crushing chamber | Beneficio operativo: Enhances throughput capacity and promotes slabby material breakage over flaking | Impacto del retorno de la inversión: Entrega hasta 10% more tons per hour at equivalent power draw compared to previous generation designs.

Construcción de marco resistente | Base técnica: Fabricated from stressrelieved steel plate with reinforced ribbing at all highstress points | Beneficio operativo: Provides longterm alignment stability under cyclical loading, protecting internal components | Impacto del retorno de la inversión: Mitigates risk of frame fatigue cracking, garantizar la integridad estructural durante un 15+ año de vida útil.

Seguridad mejorada & Utilidad | Base técnica: Centralized grease points; accessible cheek plate bolts; guarding integrated into structure | Beneficio operativo| Routine maintenance tasks are faster and safer for technicians| Impacto del retorno de la inversión| Lowers scheduled maintenance labor hours by an estimated 25%, improving site safety compliance.

Ventajas competitivas: Mejoras de rendimiento mensurables

The JC5000 Jaw Crusher is designed to outperform conventional solutions across critical metrics.

| Métrica de rendimiento | Estándar de la industria (Clase comparable) | Rendimiento documentado de la solución JC5000 | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (tiempo de actividad) | ~85% (ajuste de factorización & blockage downtime)| >92% (with hydraulic toggle & claro) | +8% |
| Vida del revestimiento (Roca abrasiva) | ~120.000 toneladas por juego (manganeso14%)| ~150,000 tons per set (Mn18% optional) | +25% |
| Eficiencia Energética (kWh/tonelada)| Varía ampliamente; baseline = 1.0x factor| Field data shows consistent reduction averaging ~0.9x factor |10% |
| Tiempo de ajuste de CSS| 24 horas con tripulación| <30 minutes with single operator |87% |

Especificaciones técnicas

Apertura de alimentación: 500mm x 250mm
Tamaño máximo de alimentación: 400milímetros
Rango de configuración del lado cerrado: 75mm 150mm
Rango de capacidad: 180 350 toneladas por hora (dependiente del material de alimentación y CSS)
Requisito de potencia de accionamiento: 75kW /100HP electric motor (estándar)
Peso de la trituradora (excluyendo motor): Aproximadamente 16 toneladas métricas
Especificaciones clave de materiales:
Frame Fabrication Grade Steel
Jaw Plates Premium manganese steel (Mn14% standard; manganeso18%, Mn22% optional)
Eccentric Shaft Forged EN24/34CrNiMo6 equivalent
Rodamientos Rodamientos de rodillos a rótula; Timken/SKF/FAG grade
Rango de temperatura de funcionamiento: 20°C a +40°C con lubricantes estándar.
Dimensiones (Largo x ancho x alto): ~3.5m x 2.8m x 2.9m

Escenarios de aplicación

Desafío del proyecto de expansión de cantera de granito:

A quarry needed to increase primary circuit throughput by 30% without expanding its footprint or major civil works. Their existing crusher created bottlenecks due to slow adjustment times and frequent liner wear checks.

Solución:

Implementation of one JC5000 Jaw Crusher as the new primary unit. Key features utilized were the hydraulic toggle for rapid product sizing changes between road base and rail ballast production runs.

Resultados:

Throughput goals were met within the first quarter. The site manager reported a 22% reduction in weekly labor hours dedicated to crusher maintenance and adjustments, reallocating personnel to other areas.

do&D Recycling Plant Upgrade Challenge:

A recycling plant processing mixed demolition waste faced excessive downtime from uncrushable materials jamming the primary jaw, requiring full shutdowns and manual clearing several times weekly.

Solución:

Replacement with a JC5000 Jaw Crusher equipped with an automatic hydraulic tramp release system integrated into the toggle mechanism.

Resultados:

Blockage events requiring full shutdown were virtually eliminated. The plant recorded a 17% increase in monthly processed volume due to reduced stoppages while protecting downstream conveyors from metal damage.

Consideraciones comerciales

Equipment pricing is structured around core configuration:

1. Base Machine Tier Includes crusher frame assembly drive sheave flywheels standard manganese liners guards lubrication system

2 Optional Feature Packages
Hydraulic Toggle Adjustment Kit Automatic Tramp Release System HeavyDuty Skid Base Frame Belt Drive Guard Package HigherGrade Manganese Liners Mn18Mn22

3 Service Support Packages Proactive maintenance plans are available including scheduled inspections parts kits priority technical support Extended warranty options can be negotiated based on application review

4 Financing Options Flexible commercial terms are offered through partnered financial institutions including equipment leasing capital loan structures or rentaltopurchase agreements tailored to project cash flow

Preguntas frecuentes Preguntas frecuentes

What power supply is required for the JC5000 A standard 75kW 400V50Hz3phase electric motor is supplied Can it be configured for diesel drive Yes skidmounted diesel drive packages are available as an option

How does the hydraulic toggle system affect reliability The system simplifies mechanics replacing dozens of manual shims It uses proven industrial hydraulic components designed specifically for highshock environments reliability data indicates no reduction in overall system uptime

What is the lead time on replacement wear parts Commonly used parts like jaw plates cheek plates are typically held in regional stock centers with availability within 48 weeks Nonstock items have a manufacturing lead time communicated upon order

Can the JC5000 handle wet sticky clayladen material While capable performance will be reduced compared to dry rock We recommend site evaluation For severe clay applications pre screening or grizzly feeding should be considered

What commercial terms are available Minimum order quantity is one 1 unit We offer comprehensive commercial support including FOB CIF DAP delivery terms based on customer location Full payment letters of credit are standard structured payment plans can be discussed