1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando la rentabilidad de su cantera?? Para gerentes de planta y contratistas de ingeniería, producing consistent, highquality railway ballast presents distinct challenges. Inconsistent feed material leads to excessive fines generation, failing stringent particle size distribution (PSD) specifications and resulting in product rejection. Frequent liner wear in crushing chambers increases maintenance intervals, provocando costosas paradas de producción. High energy consumption per ton of final product directly impacts your bottom line. Además, the need for multiple crushing stages to achieve the cubical shape required for optimal track bed stability often complicates plant layout and increases capital expenditure.

How do you increase yield of specification ballast while controlling wear costs and energy use? The efficiency of your primary crushing stage is fundamental to solving these problems.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

Esta línea de productos abarca trabajos pesados., stationary primary jaw crushers engineered specifically for highvolume quarry ballast production. The operational workflow is designed for maximum reliability: (1) memoria de sólo lectura (RunofMine) feed is delivered to the vibrating grizzly feeder, que elimina los finos naturales y evita el material de subtamaño; (2) Oversize material is directed into the deep crushing chamber of the jaw crusher for initial compression breaking; (3) The crushed material is discharged onto a main conveyor at a consistent, optimized size for secondary processing. This equipment is designed for hard rock applications (granito, basalto, trampa de roca) con alta abrasividad. It is not suited as a standalone solution for soft or highly friable rock without secondary shaping stages.

3. CARACTERÍSTICAS PRINCIPALES

Geometría aplastante agresiva | Base técnica: Steep nip angle and long stroke | Beneficio operativo: Generates higher throughput and effective size reduction in a single pass, reducing load on downstream cone crushers. | Impacto del retorno de la inversión: Increases total plant capacity by 1015%, maximizar la utilización de activos.

Construcción de marco resistente | Base técnica: Fabricated steel plate with reinforced ribbing and stressrelieved welding. | Beneficio operativo: Proporciona una durabilidad excepcional contra cargas de impacto de material no triturable., Minimizar la fatiga del marco y el riesgo de falla catastrófica.. | Impacto del retorno de la inversión: Extiende la vida útil estructural más allá 20 años bajo operación normal, proteger la inversión de capital.

Sistema de revestimiento modular | Base técnica: Interchangeable cheek plate and jaw die segments secured by wedgelocking mechanisms. | Beneficio operativo: Reduces replacement downtime from days to hours. Allows strategic rotation of wear parts to utilize full material volume. | Impacto del retorno de la inversión: Cuts liner changeout labor costs by up to 40% y aumenta la disponibilidad de la trituradora.

Ajuste hidráulico & Claro | Base técnica: Integrated hydraulic cylinders for setting adjustment and clearing tramp metal/uncrushables. | Beneficio operativo: Permite el ajuste remoto de CSS (Configuración del lado cerrado) for quick product gradation changes and safe, rapid clearing of blockages without manual intervention. | Impacto del retorno de la inversión: Minimiza las paradas no planificadas; Los datos de campo muestran una 90% reduction in downtime related to chamber blockages.

Transmisión directa & Diseño de volante | Base técnica: Hightorque motor coupled directly to eccentric shaft with optimized flywheel mass. | Beneficio operativo: Ensures consistent power transmission under peak loading conditions, maintaining constant velocity for improved particle shaping. | Beneficio operativo: Improves energy efficiency by reducing transmission losses common in Vbelt drives.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Solución de trituración de lastre de cantera | Ventaja (% mejora) |
| : | : | : | : |
| Vida del revestimiento (Roca abrasiva)| 450,000 550,000 montones| 600,000 750,000 montones| +25% promedio |
| Consumo de energía| 0.85 1.1 kWh/tonelada| 0.72 0.90 kWh/tonelada| Arriba a 18% reducción |
| Cubical Product Yield| ~65% postprimary| ~75% postprimary| +10 puntos porcentuales |
| Tiempo medio entre mantenimiento (MTBM)| ~450 horas| ~600 hours| +33% |
| Consistencia del rendimiento| +/ 15% variance during shift|< +/ 8% variance during shift| Variance reduced by nearly half |

5.ESPECIFICACIONES TÉCNICAS

Rango de capacidad: 500 1,800 MTPH (dependiente del material de alimentación y CSS)
Apertura de alimentación: Hasta 60” x 80” (1,500mm x 2.000 mm)
Requisito de energía: 200 400 kW electric drive
Especificaciones de materiales: Fabricated from ASTM A36 steel; Jaw dies available in AR400 or manganese steel (1822%); Eje forjado con acero de aleación de alta resistencia..
Dimensiones físicas clave: Rango de peso aproximado desde 85,000 kilogramos a 165,000 kilos.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C con sistemas de lubricación adecuados.

6. ESCENARIOS DE APLICACIÓN

Granite Quarry – Railway Ballast Supply Contract

Desafío: A national rail project required consistent Grade A ballast supply at over 800 Mtph but faced frequent jaw crusher liner failures every six weeks due to highly abrasive granite.
Solución: Implementation of a primary jaw crusher featuring the modular liner system in manganese steel.
Resultados: Liner life extended to nine weeks per set while maintaining target throughput quantifiable outcomes included a direct reduction in wear part costs of $135k annually and a projected increase in annual production hours due to fewer changeouts.

Basalt Aggregate Producer – Plant Modernization

Desafío: An existing plant’s primary crusher produced excessive flaky material requiring additional processing stages poor particle shape reduced final ballast yield.
Solución: Replacement with a new primary jaw crusher engineered with aggressive geometry and optimal stroke.
Resultados: Postprimary cubical product yield increased from an average of production data confirmed an overall plant yield improvement allowing the contractor to fulfill two concurrent supply contracts without expanding secondary crushing capacity.

7. CONSIDERACIONES COMERCIALES

Pricing tiers are structured based on crusher size feed opening capacity:
Tier I Standard Duty Configuration includes crusher motor drives basic guarding installation drawings
Tier II BallastOptimized Package adds hydraulic adjustment overflow chute specialized jaw die profile extended warranty
Tier III Turnkey Skid Module includes feeder scalping screen integral walkways ladders preassembled electricals

Optional features include automated lubrication systems wear monitoring probes dust suppression ring guards

Service packages are available as Bronze Silver Gold levels covering parts labor scheduled inspections Financing options include capital lease operating lease or projectbased financing terms typically ranging from months

8. Preguntas frecuentes

What upstream equipment is needed?
A vibrating grizzly feeder is strongly recommended ahead of this crusher scalp out fines protect the chamber from unnecessary wear ensure even feed distribution across the jaw length

Can this equipment process recycled concrete or asphalt?
While capable it is not optimal design focuses on hard virgin rock using it for recycling may accelerate wear due to contaminants lower ROI compared dedicated recycling impactors

¿Cuáles son los requisitos típicos de instalación??
Requires substantial reinforced concrete foundation detailed foundation drawings provided lead time from order commissioning averages months depending model site conditions

How does pricing compare total cost ownership TCO?
Initial investment may be higher than standard models however industry testing demonstrates lower TCO over year period due reduced energy consumption extended wear part life higher availability

¿Qué formación proporcionó a los operadores el personal de mantenimiento??
Comprehensive onsite training covers safe operation routine maintenance troubleshooting procedures detailed manuals video libraries accessible