1. PAINPOINT DRIVEN OPENING

Are you managing the high costs and operational disruptions inherent in primary crushing? Inconsistent feed size, abrasive ores, and unplanned maintenance create significant bottlenecks. Consider these common challenges:
Excessive Downtime: Unplanned liner changes and mechanical failures halt your entire processing line, costing thousands per hour in lost production.
Unpredictable Output: Fluctuations in gradation and capacity disrupt downstream milling and separation efficiency, compromising final product quality.
Spiraling Operating Costs: Premature wear on concaves and mantles, coupled with high energy consumption per ton, erodes your profit margins.
Safety & Labor Intensity: Traditional adjustment and maintenance procedures increase risk exposure and require skilled personnel for manual interventions.

Is your current primary crusher a reliable asset or a recurring source of cost and delay? A robust, wellengineered CE Marked Gyratory Crusher is not merely a purchase; it's a strategic investment in plant stability and throughput.

2. PRODUCT OVERVIEW

A CE Marked Gyratory Crusher is a heavyduty, continuousduty primary crushing machine designed for the first stage of size reduction in largescale mining and aggregate operations. Its core mechanism involves a gyrating mantle within a concave hopper, applying compressive force to break large feed material (often exceeding 1 meter) down to a manageable product for secondary crushing.

Operational Workflow:
1. Feed Intake: Runofmine (ROM) ore or large quarry rock is directed into the top of the crusher’s deep, rugged concave.
2. Compressive Crushing: The eccentrically gyrating mantle repeatedly approaches and recedes from the concave walls, applying progressive compression to fracture the material.
3. Discharge: Crushed product gravitates through the narrowing gap at the bottom (the closedside setting) and exits the crushing chamber for further processing.

Application Scope: Ideal for hightonnage (1,500+ tph) applications with hard, abrasive materials like granite, iron ore, copper ore, and gold ore. Best suited for fixedplant installations.

Key Limitations: Not designed for portable plants or recycling applications with high volumes of tramp metal. Requires a substantial capital investment and engineered foundation.

3. CORE FEATURES

Patented QS™ Quattro Movement | Technical Basis: Optimized eccentric throw & stroke combination | Operational Benefit: Generates a more aggressive crushing action at the top of the chamber for increased capacity while maintaining controlled discharge grading. | ROI Impact: Field data shows up to 10% higher throughput compared to conventional gyratory designs with identical feed openings.

Liner Retention System (LRS) | Technical Basis: Mechanically locks concave segments without use of backing material (e.g., epoxy or zinc). | Operational Benefit: Reduces liner changeout time by up to 50% and eliminates hazardous chemical handling. Your maintenance crew can execute safer, faster replacements. | ROI Impact: Direct labor cost savings and increased crusher availability contribute significantly to lower cost per ton.

Integrated Smart Station (ISS) | Technical Basis: Centralized PLCbased control hub monitoring mainshaft position, lubrication pressure/temperature, power draw, and bearing condition. | Operational Benefit: Provides realtime operational data and diagnostics to your plant managers, enabling predictive maintenance and preventing catastrophic failures. | ROI Impact: Minimizes unplanned stoppages; industry case studies correlate ISS use with a 30% reduction in major mechanical downtime events.

Hydroset® Tramp Release & Setting Adjustment | Technical Basis: Hydraulic cylinder supports the mainshaft for instantaneous clearing of uncrushable material and remote adjustment of the closedside setting (CSS). | Operational Benefit: Operators can clear a stalled chamber or finetune product size from the control room in minutes without entering the crusher bay. | ROI Impact: Eliminates manual jacking operations, enhancing safety and maximizing productive uptime between shifts.

Spirally Grooved Mainshaft Bearing | Technical Basis: Precisionengineered grooves ensure optimal oil film distribution across the entire bearing surface under extreme load. | Operational Benefit: Extends bearing service life under continuous heavy load cycles by reducing metaltometal contact points that cause wear. | ROI Impact: Defers major capital overhauls; documented instances show bearing life extensions of 1520% in comparable duty cycles.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | CE Marked Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (%) | 92 94% annual average | >96% annual average achievable| +24% improvement |
| Liner Change Time (Hours) | 36 48 hours for full concave/mantle set| <24 hours with LRS system| ~50% reduction |
| Energy Consumption (kWh/t) Varies by material.| Baseline = 100%| Average reduction of 57% via optimized kinematics| ~57% improvement |
| Mean Time Between Failure (MTBF) Major Components| Standard interval based on OEM schedule.| Up to 20% longer intervals via enhanced bearing & monitoring systems.| +20% extension |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent from ~1,500 to over 10,000 metric tons per hour.
Feed Opening: Ranges from 600mm x 1400mm up to 1800mm x 4500mm.
Motor Power: Typically between 300 kW and 1,000+ kW depending on model size.
Total Weight: From approximately 150 tonnes to over 500 tonnes for largest models.
Key Material Specifications: Highstrength cast steel mainframe; Austenitic Manganese Steel (AMS) or patented alloy concaves/mantles; forged alloy steel mainshaft.
Operating Temperature Range: Lubrication system engineered for stable operation from 20°C to +50°C ambient conditions.
Compliance & Certification: CE Marking confirms conformity with EU safety health & environmental protection directives (Machinery Directive).

6. APPLICATION SCENARIOS

Copper Mine Expansion – Throughput Constraint

Challenge: A major copper operation needed to increase plant throughput by 25% but was constrained by their existing primary crushing circuit’s peak capacity.
Solution: Installation of a new largecapacity CE Marked Gyratory Crusher with an optimized stroke profile.
Results: Achieved sustained throughput at design capacity of +28%. Consistent product gradation improved SAG mill feed stability.

Granite Aggregate Quarry – Operating Cost Reduction

Challenge: High liner wear costs and extensive downtime for manual CSS adjustments were making primary crushing economically inefficient.
Solution: Retrofitted an existing gyratory crusher with modern liners featuring an LRS system paired with an automated Hydroset system.
Results: Liner change time reduced from 40 to 18 hours per event. Remote CSS adjustments saved an estimated 120 labor hours annually while optimizing yield for premium products.

Iron Ore Processing – Reliability Focus

Challenge: Unpredictable bearing failures in a harsh environment caused catastrophic downtime events averaging over one week per incident.
Solution: Procurement of a new CE Marked Gyratory Crusher featuring an advanced spirally grooved mainshaft bearing design coupled with Integrated Smart Station monitoring.
Results: Predictive alerts from ISS allowed planned interventions during scheduled stops. Bearing service life increased by an average of three months between planned services over previous models used onsite.

COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on size/capacity:
Tier I (6k tph): Customengineered solutions for megaprojects

Optional Features:
Automated Wear Monitoring System
Dust Suppression Sealing Package
Extended Wear Component Kits

Service Packages:
1.Basic Warranty Coverage
2.Planned Maintenance Agreement – includes scheduled inspections & parts discounts
3.FullService Contract – covers parts & labor under fixed annual cost

Financing Options are available through partner institutions including equipment leasing structures tailored to project cash flow profiles or traditional term loans secured against machinery assets

FAQ

Q1 What does 'CE Marking' specifically guarantee about this gyratory crusher?
A1 CE Marking confirms compliance with mandatory European Union directives related primarily to machinery safety (2006/42/EC). It assures that essential health,safety,and environmental protection requirements have been met during manufacture including risk assessment documentation available upon request

Q2 How does this equipment integrate into our existing PLC/SCADA control system?
A2 The crushers are equipped standard industrial communication protocols such as Profibus Modbus TCP/IP Ethernet/IP allowing direct integration into most modern plantwide control systems via its onboard Integrated Smart Station interface module

Q3 What typical lead times apply from order placement commissioning?
A3 Lead times vary significantly based model complexity current manufacturing load Standard Tier II models generally have lead time between months months Large Tier III custom units may require months engineering fabrication delivery Project planning should account these timelines accordingly

Q4 Are performance guarantees offered regarding throughput liner life?
A4 Yes performance guarantees regarding rated capacity power consumption are standard commercial terms Guarantees specific wear rates consumables like liners are typically offered as separate negotiated agreements based agreed reference operating conditions feed material characteristics

Q5 What level foundation preparation required installation?
A5 Detailed geotechnical foundation drawings specifications are provided part technical documentation package Foundations typically require significant mass reinforced concrete designed absorb dynamic loads transmit them substrate Professional civil engineering review sitespecific conditions mandatory prior installation