1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are escalating operational costs and unpredictable downtime eroding your quarry's profitability? Para gerentes de planta y contratistas de ingeniería, ballast production presents distinct challenges that directly impact the bottom line. Los puntos débiles comunes incluyen:
Generación excesiva de multas: Arriba a 1520% of processed material can fall below spec, turning potential revenue into waste stockpiles.
Alto consumo de piezas de desgaste: The abrasive nature of trap rock, granito, and basalt leads to premature liner and hammer failure, causing frequent, costly maintenance stops.
Inconsistent Product Cubicity: Poor particle shape in the final product reduces track bed stability and can lead to product rejection.
Ineficiencia energética: Older crushing stages consume disproportionate power for the usable tonnage produced, inflating operational expenses.
Capacidad inflexible: Fixed plants struggle to adapt to fluctuating demand, creating bottlenecks or underutilization.

Is your current setup equipped to maximize yield from every ton of feed while controlling maintenance costs and energy consumption? The right primary crushing equipment is the foundational answer.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: ODM QUARRY PRIMARY JAW CRUSHER FOR BALLAST PRODUCTION

This product line focuses on heavyduty primary jaw crushers engineered specifically for highvolume ballast production from hard, abrasive feed materials. As an ODM (Fabricante de diseño original), we provide customized crushing solutions built to your precise operational parameters and site constraints.

Flujo de trabajo operativo:
1. Reducción Primaria: memoria de sólo lectura (RunofMine) roca de cantera, typically up to 800mm in size, is fed into the crusher's robust vibrating grizzly feeder (VGF VGF) section.
2. Pre-selección & Aplastante: The VGF removes natural fines and bypasses subsize material, Dirigir solo roca de gran tamaño a la cámara de trituración.. The deep,symmetrical jaw chamber performs the initial compressive break.
3. Product Shaping: The kinematics of the jaw plate motion are optimized to promote interparticle crushing, enhancing particle cubicity on the first pass.
4. Descargar & Transporte: Crushed material is discharged at a consistent CSS (Configuración del lado cerrado) onto the primary conveyor for transport to secondary screening and crushing stages.

Ámbito de aplicación & Limitaciones:
Ideal para: Primary crushing of hard, roca ígnea abrasiva (granito, basalto) and dense limestone for railway ballast and construction aggregates.
Limitaciones: No apto para pegajosos., claybound materials without prescreening/scalping. Feed size is constrained by crusher model inlet dimensions.

3. CARACTERÍSTICAS PRINCIPALES

HeavyDuty Rolled Steel Frame | Base técnica: Singlepiece, stressrelieved fabrication | Beneficio operativo: Elimina el agrietamiento por fatiga del marco bajo cargas cíclicas; provides stable platform for precision bearing alignment | Impacto del retorno de la inversión: Extended structural life exceeding 20+ years reduces capital replacement risk.

Geometría de cámara optimizada & Cinemática | Base técnica: ST/DT (Steep/Deeper Toggle) cavity design with aggressive nip angle | Beneficio operativo: Aumenta el rendimiento hasta en 10% at same power draw; promotes better particle shape for downstream processing | Impacto del retorno de la inversión: Higher yield of inspec product per operating hour directly increases revenue.

Hydroset CSS Adjustment System | Base técnica: Hydraulic cylinders support the toggle seat for safe setting adjustment | Beneficio operativo: Closedside setting changes can be made in minutes under load or during clearing strokes, without manual shims | Impacto del retorno de la inversión: Reduce el tiempo de inactividad por cambios de tamaño del producto en más de 80%, enhancing plant flexibility.

LongLasting Manganese Jaws with Clamp Systems | Base técnica: Isovitric supergrade manganese steel with reversible design; mechanical clamp system for fast replacement | Beneficio operativo: Jaw life increased by 2530%; changeout time reduced from days to a single shift | Impacto del retorno de la inversión: Lowers costperton for wear parts and significantly increases plant availability.

Integrated PreScreening Grizzly Feeder | Base técnica: Boltin grizzly sections with adjustable slope and gap settings | Beneficio operativo: Removes up to 20% of fines prior to crushing chamber, reducing unnecessary wear and improving chamber efficiency | Impacto del retorno de la inversión: Directly lowers wear part consumption and power cost per ton of crushed material.

Sistema de engrase automatizado centralizado | Base técnica: Programmable lubrication unit serving all key bearing points | Beneficio operativo: Garantiza intervalos óptimos de lubricación de rodamientos.; prevents both under and overgreasing failures | Impacto del retorno de la inversión: Extends critical bearing service life by an average of 35%, preventing catastrophic downtime.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Promedio) | ODM Quarry Jaw Crusher Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (tiempo de actividad) | ~8590% (programado & paradas no programadas) |> 94% (based on field monitoring data) |> +5% Mejora |
| Costo de desgaste por tonelada (Roca abrasiva) $0.12 $0.18/tonelada| 25% Reducción |
| Consumo de energía específico| Varía ampliamente; older units > 0.8 kWh/ton @ CSS 150mm| 19% Reducción |
| Generación de multas (<22milímetros)| ~1822% of total feed| 30% Reducción |
| Índice de descamación del producto (Objetivo 30% after primary stage| Consistently Improved Shape |

5. ESPECIFICACIONES TÉCNICAS

Modelo Rango Capacidad: 400 1,800 toneladas por hora (TPH), depending on feed material and closedside setting.
Apertura de alimentación: From 1,000mm x 650mm up to 1,500mm x 1,200mm.
Requisitos de energía: Drive motor from 90 kW hasta 300 kilovatios; total installed power including feeder hydraulics specified per model.
Especificaciones de materiales: Highstrength welded frame (Acero S355JR); Isovitric manganese crusher jaws; forged alloy steel eccentric shaft with largediameter spherical roller bearings.
Dimensiones físicas & Peso: Approximate weights from 35 toneladas a 120 montones; detailed layout drawings provided for foundation planning.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; dust sealing compliant with ISO standard levels; noise emissions designed below 105 dB(A) en las estaciones del operador.

6. ESCENARIOS DE APLICACIÓN

Cantera de Hard Rock suministra proyecto ferroviario nacional

Desafío: A granite quarry needed to supply over 2 million tons of Type I ballast within a strict timeline but faced excessive wear costs and fines generation (>22%) from their existing primary crusher.
Solución: Implementation of a customconfigured ODM heavyduty jaw crusher with an integrated aggressive grizzly feeder profile optimized for their specific granite blend.
Resultados: Fines generation reduced to below spec at <14%. Wear part lifecycle extended by approximately28%. The project was completed ahead of schedule due to sustained throughput rates averaging12% above target.

Aggregate Producer Expanding into Rail Ballast Market

Desafío: An established aggregate producer lacked a primary stage capable of producing the consistent cubicity required by rail authorities without excessive secondary recrushing.
Solución: Installation of an ODM jaw crusher with a specially engineered chamber profile focused on firstpass shape optimization.
Resultados: Final product Flakiness Index achieved directly after primary crushing met rail specification (<25%), reducing load on secondary cone crushers by approximately15%. This allowed reallocation of secondary capacityto other product lines.

7. CONSIDERACIONES COMERCIALES

Our ODM approach provides structured commercial flexibility:

Niveles de precios de equipos: Based on model size/capacity range:
Nivel I (1200 TPH): Fully customized solutions with advanced monitoring packages included.

Características opcionales & Paquetes:
Advanced PLC automation package with loadregulation logic
Wear part monitoring sensors
Integración del sistema de supresión de polvo.
Modular skidbase design for faster installation

Paquetes de servicios:
Basic Warranty Package
Comprehensive Service Agreement including scheduled inspectionsand parts discounts
Instalación llave en mano & Soporte de puesta en marcha

Opciones de financiación:
We work with international export credit agenciesand equipment financing partners t o offer leasetoown arrangements , mediumterm loans , or tailored rentalpurchase agreements t o align w ith your project cash flow .

8.Preguntas frecuentes

q:What level o f customization i s possible w ith your ODM jaw crushers?
A.We can modify several parameters including feeder dimensions ,grizzly bar configuration ,discharge conveyor interface points ,and motor mounting positions t o ensure compatibility w ith your existing plant layoutand feed system .

Q.How does this equipment improve our overall plant efficiency beyond justtheprimary stage?
A.B y deliveringa more consistent ,cubicalproductatthefirststage,yoursecondaryand tertiarycrushers operate more efficiently .This reduces circulating loadsand improves finalproductyieldwhile loweringtotalplantpowerconsumption .

q:What i sthetypical delivery lead timeforacustomized unit?
A.Forstandardmodels withinourTierI&IIrange ,lead timesaretypically1622weeksfromorderconfirmation .FullycustomizedTier IIIsolutionsrequire detailed engineeringand mayextendto28weeks .Proactive planningi srecommended .

Q.Arewearparts interchangeablewithothercrusherbrands?
A.No .Ourwearpartsaredesigned specificallyforourchambergeometryandkinematics t oensureoptimalperformanceand longevity .We providecomplete technicaldrawingsforinventory planning .

Q.What kindo f foundationi srequired ?
A.We providecomprehensivefoundationdrawingswitheachorderincludingallstaticand dynamicloaddata .Foundationsaretypicallyreinforcedconcrete ;our engineerscanreviewyoursitespecificplansuponrequest .

Q.Doyouoffertrainingforouroperatorsandmaintenancestaff ?
A.Y es.O nsiteoperationalandsafetytrainingduringcommissioningi sincludedwith everysale .Additionalmaintenancetrainingmodulesareavailableaspartofourservicepackages .

Q.Whatarethekeyfactorsin determiningthecorrectmodelsizeforourapplication ?
A.Capacityselectionisbasedonfourprimaryfactors :yourmaximumfeedsizematerialhardnessorBWI( BondWorkIndex ),desiredproductsize( CSS ),andrequiredhourlytonnage .Ourtechnicalteamwillanalyze yoursamplesandspecificationst orecommendtheoptimalmodel