1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are you managing a stone quarry operation where profit margins are consistently pressured by equipment performance? The challenges of primary crushing are often the bottleneck. Considere estos obstáculos operativos comunes:
Tiempo de inactividad excesivo para mantenimiento: Cambios frecuentes de revestimiento, fallas inesperadas en los rodamientos, and wear part replacement halt your entire production line, costando miles por hora en ingresos perdidos.
Tamaño de alimentación inconsistente & Rendimiento: puente, segregación, and irregular feed from the quarry face lead to poor crusher cavity fill, reducing capacity and increasing wear unevenly.
Altos costos operativos: Creciente consumo de energía por tonelada de material procesado, coupled with the high and frequent cost of wear parts like mantles, cóncavo, y placas de mandíbula, directly erode profitability.
Inconsistencia en la calidad del producto: Inability to reliably control topsize output or an excessive proportion of flaky material can impact downstream processes and final product marketability.
Seguridad & Accessibility Concerns: Routine inspections and maintenance tasks that are timeconsuming or require personnel to work in hazardous proximity to the equipment.

Is your primary crushing station a source of reliability or a recurring cost center? The right contract manufacturer for your stone quarry crushing plant addresses these issues at the design phase, focusing on total cost of ownership rather than just initial purchase price.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

This content outlines the critical considerations for a stationary primary jaw crusher station within a complete stone quarry crushing plant. Designed as the first mechanical reduction stage, this system is engineered for high availability and low costperton in hard rock applications like granite, basalto, y piedra caliza.

Flujo de trabajo operativo:
1. Consumo de alimento: Dump trucks or wheel loaders discharge runofquarry (ROQ) material into a rugged vibrating grizzly feeder (VGF VGF).
2. Pre-selección & Eliminación de multas: The VGF scalps out natural fines and subcrushsize material via its grizzly bars, bypassing the crusher to increase efficiency and reduce wear.
3. Reducción Primaria: Oversize material is conveyed into the jaw crusher cavity, where compressive force between a fixed and a moving jaw plate fractures the rock.
4. Descargar & Transporte: El material triturado se descarga en un transportador principal de producto para su transporte al triturado secundario o almacenamiento..

Ámbito de aplicación & Limitaciones:
Alcance: Ideal para alto tonelaje, abrasive hard rock quarries requiring a robust primary breaker. Optimal for material with compressive strength up to 400 MPa.
Limitaciones: No apto para pegajosos., materiales ricos en arcilla sin preprocesamiento. A gyratory crusher may offer superior throughput for capacities exceeding 1,500 tph in certain configurations.

3. CARACTERÍSTICAS PRINCIPALES

Alimentador Grizzly Vibrante de Servicio Pesado (VGF VGF) | Base técnica: Highstrength steel plate construction with boltin AR liners | Beneficio operativo: Regulates feed rate to the crusher, elimina los puentes, removes fines to prevent crusher packing | Impacto del retorno de la inversión: Increases effective crusher capacity by up to 15% and reduces unnecessary wear on crusher components

WedgeBased Jaw Plate Adjustment System | Base técnica: Mechanically locked wedges replace traditional shim plates | Beneficio operativo: Permite seguridad, fast CSS adjustment and jaw plate changes from the crusher’s nondrive side in under two hours | Impacto del retorno de la inversión: Reduce el tiempo de inactividad para ajustes de rutina en aproximadamente 60%, maximizing productive operating hours

Geometría optimizada de la cámara de trituración | Base técnica: Cinemática modelada por computadora y diseño de ángulo de contacto. | Beneficio operativo: Promotes deepbed crushing throughout the chamber for consistent particleonparticle breakage | Impacto del retorno de la inversión: Produces a more cubical product shape (improving secondary crush efficiency) and extends jaw plate service life by distributing wear more evenly

Base de motor integrada & Protector de cinturón | Base técnica: Unified steel fabrication housing crusher motor(s) y conducir guardias | Beneficio operativo: Eliminates complex field alignment during installation; proporciona seguridad, integral guarding compliant with site safety standards | Impacto del retorno de la inversión: Reduces installation time and cost by up to 30%, ensuring faster commissioning

Puntos de engrase centralizados & Puertos de monitoreo de condición | Base técnica: Lube lines routed to accessible groundlevel stations with ports for vibration/temperature sensors | Beneficio operativo: Enables daily lubrication and health checks without operators needing to access elevated platforms near moving parts | Impacto del retorno de la inversión: Enhances preventative maintenance adherence, improving bearing life and preventing catastrophic failures

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Nuestra solución de planta trituradora de cantera de piedra | Ventaja (% Mejora) |
| : | : | : | : |
| Tiempo de cambio de revestimiento | 68 horas (Placas de mandíbula) | < 2 horas (Placas de mandíbula) | ~70% más rápido |
| Eficiencia Energética| 0.85 1.1 kWh/tonelada procesada| Objetivo: 10% mejora |
| Disponibilidad de trituradora| ~9294% (programado & no programado)| Objetivo de diseño: >96%| ~34% de aumento |
| Utilización de piezas de desgaste| ~6070% of theoretical weight used before changeout| Design enables use of >85% of liner mass| ~25% better utilization |

5. ESPECIFICACIONES TÉCNICAS

Referencia del modelo: STQPrimary1442HD
Tipo de trituradora: Trituradora de mandíbula de palanca única de servicio pesado
Apertura de alimentación: 1400mm x 1100 mm (55" incógnita 42")
Tamaño máximo de alimentación: 1000milímetros (40") longitud del borde
Configuración del lado cerrado (CSS) Rango: 150mm 300 mm (6" 12")
Rango de capacidad: 450 850 tph métricas (dependent on feed gradation & CSS)
Requisito de potencia de accionamiento: 200 kilovatios (275 caballos de fuerza), electric motor with softstart compatibility
Total Plant Power Demand (Feeder/Crusher/Conveyors): Aprox.. 350 kilovatios
Especificaciones clave de materiales: Placa de acero fabricada con marco principal; Jaw plates Manganese steel alloy; Shaft forged alloy steel; Bearings spherical roller type.
Huella aproximada (Largo x ancho): 18m x 8m
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; rodamientos sellados contra el polvo; weather protection covers standard.

6. ESCENARIOS DE APLICACIÓN

Proyecto de Ampliación de Cantera de Granito

Desafío: An existing granite quarry needed to expand production but was constrained by an aging primary plant causing over 40 hours of unplanned downtime monthly due to reliability issues.
Solución: Contract design and supply of a complete new primary stone quarry crushing plant station built around a heavyduty jaw crusher with enhanced accessibility features.
Resultados: Postinstallation data showed plant availability increased from 88% a 96%. Unplanned downtime was reduced by over 90%, enabling the site to meet its expanded production target within six months.

Basalt Aggregate Producer Seeking Cost Control

Desafío: A producer faced volatile profitability due to uncontrollably high energy costs per ton and rapid wear part consumption in their primary stage.
Solución: Implementation of an optimized plant design featuring chamber geometry focused on energyefficient breakage and a feeder system that removed more fines prior to crushing.
Resultados: Field data tracked over one year showed a reduction in specific energy consumption from 0.98 kWh/ton to 0.82 kWh/ton—a direct utility cost saving—and extended average jaw plate life by approximately 22%.

7. CONSIDERACIONES COMERCIALES

Our approach as your contract manufacturer is based on transparent value engineering:

Niveles de precios
1. Standard Plant Package includes core equipment as specified above with basic walkways/platforms.
2.Optimized Plant Package includes additional features such as dust suppression system integration advanced condition monitoring sensor packages automated grease systems (+1015%)
3.Turnkey Project Package includes full civil design support installation supervision commissioning services (+varía)

Optional Features include metal detection systems tramp iron relief automation hydraulic setting adjustment vs manual modular skid designs for faster relocation

Paquetes de servicios:
• Commissioning Support Onsite training operational readiness review
• Planned Maintenance Contracts Guaranteed parts supply scheduled inspections fixed annual cost models
• Performance Audits Annual review of throughput wear rates efficiency recommendations

Financing Options available through our partners include capital lease operating lease longterm rentaltoown structures tailored typically over 3 7 10términos anuales

8.Preguntas frecuentes

Q What if my current secondary crushers are not from your company? Is compatibility an issue?
A No Our stone quarry crushing plant is designed as an independent modular station Output specifications including product size distribution are engineered based on your input requirements ensuring seamless interface with any downstream equipment via proper transfer conveyors

Q How does this solution address my high energy costs?
A Energy efficiency is engineered into multiple components including optimized feedercrusher interaction efficient drive motor selection correctly sized gearboxes The overall system design aims minimize bottlenecks that cause motors run underloaded which inefficient Field data shows our optimized plants typically achieve measurable reductions specific energy consumption kWh per ton processed

Q What guarantees do you provide on performance metrics like throughput?
A We provide process performance guarantees based agreedupon feed material characteristics These are detailed commercial terms within contract specifying test methods duration We guarantee mechanical performance structural integrity workmanship standard industryleading warranties major components

Q Can you accommodate limited space on my existing site?
A Yes As contract manufacturer we specialize designing plants fit constrained layouts offering modular configurations vertical arrangements reduce footprint compared traditional horizontal flow designs Detailed layout studies conducted during proposal phase ensure feasibility before commitment made

Q What typical lead time expected from contract signing delivery?
A For standard configured stone quarry crushing plant lead times typically range 6 9 months depending complexity current manufacturing schedule Expedited options may available additional cost Longlead items like castings forgings identified early process