1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mineral processing margins? For plant managers and engineering contractors, the primary crushing stage is often the source of critical bottlenecks. Common challenges include:
Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical failures halt your entire production line, costing thousands per hour in lost throughput.
High Wear Part Consumption: Aggressive or abrasive feed material leads to premature jaw plate wear, driving up your costperton and creating inventory management headaches.
Inconsistent Product Gradation: A worn or poorly designed crusher chamber fails to maintain a consistent CSS (Closed Side Setting), resulting in offspec product and recrushing cycles.
Rigid Infrastructure Demands: Many jaw crushers require extensive, costly foundations and are not suited for modular or semimobile plant designs, limiting operational flexibility.
Energy Inefficiency: Older designs with inefficient kinematics consume more power per ton of processed material, directly impacting your bottom line.

What if your primary crusher could deliver predictable maintenance intervals, reduce wear costs by a measurable percentage, and adapt to evolving site requirements? The solution requires an engineered approach focused on reliability and total cost of ownership.

2. PRODUCT OVERVIEW

The Bespoke JC5000 is a heavyduty, singletoggle jaw crusher engineered for highcapacity primary crushing in quarrying, mining, and demolition recycling applications. Its design prioritizes mechanical robustness and operational efficiency for processing hard rock, ore, and concrete.

Operational Workflow:
1. Feed Intake: Large feed material (up to 1300mm) is delivered via dump truck or wheel loader into the vibratory grizzly feeder (optional), which bypasses fines to optimize chamber loading.
2. Crushing Action: Material enters the deep, nonchoking crushing chamber. The aggressive elliptical stroke of the singletoggle mechanism applies high inertia forces to reduce material by compression.
3. Discharge & Conveyance: Crushed product exits at the bottom discharge point with a consistent gradation, ready for secondary processing via conveyor.

Application Scope: Ideal for hightonnage primary crushing stations processing granite, basalt, iron ore, and recycled concrete. Not recommended for sticky, plastic clays or as a standalone unit for producing fine sand specifications without downstream crushing stages.

3. CORE FEATURES

Deep Chamber Geometry | Technical Basis: Optimized nip angle and long crushing stroke | Operational Benefit: Increased capacity per stroke and reduced risk of bridging/choking at the feed opening | ROI Impact: Higher average throughput (tph) maximizes plant utilization

HeavyDuty Roller Bearing Design | Technical Basis: Spherical selfaligning roller bearings on main shaft | Operational Benefit: Handles high radial and thrust loads with greater efficiency than bronze bushings | ROI Impact: Lower friction reduces power draw by approximately 812% versus comparable bushing designs

Hydraulic CSS Adjustment & Overload Protection | Technical Basis: Integrated hydraulic cylinders for toggle plate tensioning | Operational Benefit: Closed Side Setting can be adjusted quickly under load; system automatically releases to clear tramp metal | ROI Impact: Minimizes unplanned stops for clearing blockages; allows rapid product size changes with less operator intervention

BoltIn Wedge Lock Jaw Plate System | Technical Basis: Mechanically locked wedge system without epoxy backing material | Operational Benefit: Jaw plate changeout time reduced to under 4 hours with standard site tools | ROI Impact: Direct labor savings during maintenance windows; increases plant availability

Modular Frame Construction | Technical Basis: Fabricated steel sections with precision machined locating pads | Operational Benefit: Simplifies transport, reduces foundation requirements, and allows for future relocation or plant reconfiguration | ROI Impact: Lower capital expenditure on civil works; preserves asset value through redeployability

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | Bespoke JC5000 Solution | Advantage (% improvement) |
| : | : | : | : |
| Average Liner Life (Abrasive Granite) | 180,000 220,000 tonnes | 260,000 300,000 tonnes | +30% extended service life |
| Power Consumption per Tonne Crushed| ~0.85 kWh/t | ~0.75 kWh/t| ~12% reduction in energy cost |
| Mean Time Between Failure (MTBF) Major Components| ~2,000 hours| ~2,800 hours| +40% increase in reliability |
| Total Maintenance Hours per Year Scheduled & Unscheduled| Estimated 120150 hours| Estimated 80100 hours| Up to 33% reduction in labor |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm (51" x 40")
Maximum Feed Size: 1100mm edge length (43")
Closed Side Setting (CSS) Range: 150mm 300mm (6" 12")
Capacity Range (Varies by Material & CSS): 450 850 tonnes per hour
Drive Power Requirement: 200 kW (268 HP) electric motor
Total Weight (Crusher Only): Approximately 62,000 kg
Key Material Specifications:
Main Frame: Hightensile steel plate (Grade S355J2)
Swing Jaw Die: Manganese steel (14% Mn), reversible
Eccentric Shaft: Forged alloy steel EN24T
Operating Temperature Range: 25°C to +45°C (13°F to +113°F)

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: An existing quarry needed to increase primary circuit output by 35% but had limited space for new foundation works. Downtime during installation was also a critical constraint.
Solution: Implementation of a modular Bespoke JC5000 jaw crusher on a prefabricated support structure with a lowprofile hopper.
Results: Installation was completed in 40% less time than traditional methods due to simplified foundations. The plant achieved the target throughput increase of 35%, with energy monitoring showing a 9% reduction in specific power consumption compared to the older unit.

Iron Ore Processing Plant Upgrade

Challenge: Excessive wear on jaw plates from highly abrasive ore resulted in liner changes every six weeks at significant cost and production loss.
Solution: Replacement of an older doubletoggle crusher with the Bespoke JC5000 featuring its boltin wedge system and optimized chamber geometry.
Results: Field data shows jaw plate life extended from an average of six weeks to nine weeks—a 50% improvement—reducing annual liner costs by onethird. The hydraulic adjustment system also allowed operators to compensate for wear more effectively between changes.

7. COMMERCIAL CONSIDERATIONS

The Bespoke JC5000 is offered in three configured tiers:
1. Base Unit Tier: Includes core crusher assembly with standard motor drives and basic instrumentation.
2. PlantReady Tier: Integrates matched grizzly feeder product conveyor walkways ladders safety guards motor starters PLC control panel
3. Modular SkidMounted Tier Full semimobile package on a heavyduty skid frame requiring only hookup to power utilities

Optional features include automated lubrication systems dust suppression kits various jaw plate tooth profiles feed chute extensions

Service packages are available from annual inspection plans comprehensive partsandlabor maintenance agreements Extended warranty coverage up five years is offered subject specific operating conditions Financing options including operating lease capital lease loan structures can be structured over terms three seven years align investment cash flow generation

8 FAQ

Q What existing secondary tertiary equipment compatible JC5000?
A The JC5000 designed produce well graded feed material typical cone impact crushers Its discharge setting range gradation curve data provided ensure compatibility your downstream circuit

Q How does hydraulic adjustment system affect daily operation?
A Operators can check adjust crusher setting minutes using remote station reducing need enter equipment area making product size adjustments responsive market demands

Q What typical lead time delivery commissioning?
A Standard units have lead time months from order confirmation Full modular plants require additional engineering Site commissioning supervised our engineers typically requires five seven working days

Q Are wear spare parts readily available globally?
A Yes standardized components common consumables like jaw plates side liners held regional distribution centers ensuring availability Critical bearing shaft assemblies available under expedited shipping programs

Q Can this crusher integrated into existing automated control system?
A Yes the JC5000 equipped standard Modbus RTU communication protocol allowing integration most SCADA PLC systems monitoring key parameters like power draw hydraulic pressure provide performance data