1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Key challenges in gyratory crusher operations directly impact your bottom line:
Unscheduled Downtime: Bearing failures or mainshaft issues can halt your entire processing line for days, costing hundreds of thousands in lost production.
High Maintenance Costs: Frequent, laborintensive liner changes and component wear consume both maintenance budgets and valuable operating hours.
Inconsistent Throughput & Product Size: Fluctuations in feed material or wear over time lead to offspec product, creating bottlenecks and reducing downstream efficiency.
Excessive Energy Consumption: Older or inefficient designs draw more power per ton processed, a fixed cost that significantly impacts operating margins.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The solution requires a crusher engineered not just for peak performance, but for sustained, predictable operation under the most demanding conditions.

2. PRODUCT OVERVIEW

The Custom Gyratory Crusher is a heavyduty, primary crushing machine designed for hightonnage, continuous operation in largescale mining and aggregate production. It performs compressive crushing via a gyrating mantle within a concave hopper.

Operational Workflow:
1. Feed Intake: Runofmine (ROM) ore or large quarry rock is directly dumped into the top of the crusher’s deep, nonchoking concave.
2. Compressive Crushing: The eccentrically gyrating mantle repeatedly advances and recedes from the concave liners, applying massive compressive force to reduce material size.
3. Discharge Setting Control: The crushed product exits through the adjustable bottom setting (ABS), with size determined by the closedside setting (CSS) between the mantle and concave at their lowest point.
4. Discharge & Conveyance: Sized material is discharged onto a primary conveyor for transport to the next stage of processing.

Application Scope: Ideal for primary crushing of abrasive hard rock (iron ore, copper ore, granite), hightonnage aggregate production, and heap leach applications requiring coarse product. Not recommended for lowtonnage operations, soft or nonabrasive materials only, or sites with severe space constraints where a jaw crusher may be more appropriate.

3. CORE FEATURES

Patented QS™ Quill Shaft System | Technical Basis: Isolated eccentric motion with hydrostatic lubrication | Operational Benefit: Eliminates metaltometal contact in the eccentric assembly, drastically reducing wear and risk of catastrophic failure | ROI Impact: Field data shows up to 40% longer service intervals for the eccentric system and a documented 60% reduction in related unscheduled downtime.

INTEGRAL™ Concave & Mantle Liner System | Technical Basis: Interlocking alloy segments with optimized chamber geometry | Operational Benefit: Provides more consistent product gradation throughout liner life and reduces changeout time by up to 30% compared to traditional designs | ROI Impact: Lower liner cost per ton crushed and increased crusher availability for production.

SMARTSENSE™ Bearing Monitoring | Technical Basis: Integrated vibration, temperature, and pressure sensors on critical bearings | Operational Benefit: Your maintenance team receives realtime health data and predictive alerts, enabling conditionbased maintenance planning | ROI Impact: Prevents unexpected bearing failures, protects against secondary damage to shafts and housings.

HYDROSET® PLUS Chamber Clearing & Adjustment | Technical Basis: Dualfunction hydraulic ram system for setting adjustment and automated chamber clearing | Operational Benefit: Operators can adjust CSS under load or clear a stalled cavity remotely in minutes from the control room | ROI Impact: Maximizes uptime; eliminates hours of manual clearing efforts and associated safety risks.

HEAVYDUTY Spiral Bevel Gear & Pinion | Technical Basis: Forged alloy steel gears with computeroptimized tooth profile | Operational Benefit: Transmits high torque smoothly with minimal noise and vibration, even under uneven loading conditions | ROI Impact: Industry testing demonstrates a typical service life extension of 25% over standard gear sets under comparable duty cycles.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Average | Custom Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled Runtime) | 9294% | 96.5%+ | +35% |
| Liner ChangeOut Time (Hours) | 2436 hrs | 1620 hrs | ~40% Faster |
| Energy Consumption (kWh/t) Baseline Ore| 0.8 1.2 kWh/t| 0.65 0.9 kWh/t| Up to 20% More Efficient |
| Mean Time Between Failure (MTBF) Eccentric System| ~12,000 hrs| >18,000 hrs| +50% Reliability |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable models from 2,000 tph to over 10,000 tph.
Feed Opening: From 1,070 mm (42”) up to 1,520 mm (60”) dependent on model.
Motor Power Requirement: Typically 375 kW to 750 kW (500 HP to 1000 HP+), supplied at 6.6 kV or as required.
Total Weight: Ranges from approximately 150 tonnes to over 400 tonnes for largest configurations.
Key Material Specifications:
Main Frame & Top Shell: Highstrength fabricated steel with stressrelieving treatment.
Mainshaft: Forged from highalloy nickelchromiummolybdenum steel.
Concave & Mantle Liners: Manganese steel alloys (14%18% Mn), optional chromewhite iron or composite alloys for specific abrasion/corrosion applications.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust seals rated for harsh environments; optional heating/cooling systems available.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A planned expansion required a primary crusher capable of handling an additional 8 million tonnes per annum of highly abrasive porphyry ore without increasing footprint or headcount disproportionately.
Solution: Installation of one Custom Gyratory Crusher with INTEGRAL™ liners configured for coarse crushing ahead of SAG mills.
Results: Achieved sustained throughput of 4,500 tph at a consistent P80 of 150mm. Liner life increased by an average of 15%, contributing to a calculated total cost per tonne reduction of approximately $0.12 across the crushing circuit.

HighProduction Granite Quarry

Challenge: Frequent downtime due to tramp metal events causing damage and lengthy cavity clearing procedures was limiting annual output targets.
Solution: Implementation of our gyratory crusher equipped with the HYDROSET® PLUS system and SMARTSENSE™ monitoring.
Results: Cavity clearing events reduced from an average operational delay of 8 hours to under 45 minutes per incident. Annual plant availability increased by over 300 hours (12+ days), directly translating to an additional ~450k tonnes crushed per year within existing shifts.

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is structured into three primary tiers based on size/capacity (CGC50 Series, CGC60 Series, CGC72 Series) with base configurations including core drive system controls motor starter lubrication unit

Optional features include:
Advanced automation packages remote diagnostic telemetry special alloy liner packages dust suppression ring

Service packages are offered separately:
Bronze (Basic Warranty) Silver (Planned Inspection & Parts Discount) Gold (FullService Contract including scheduled labor parts predictive monitoring)

Financing options are available through our partners including capital lease operating lease project financing terms typically structured over years

FAQ

What is the typical installation timeline?
From delivery onsite mechanical erection electrical connection commissioning full operation typically requires weeks depending on foundation readiness site support

How does this crusher integrate with my existing control system?
The crushers PLC is designed for interoperability providing standard communication protocols Modbus TCP/IP Profibus We supply full interface documentation

Can you provide wear part cost guarantees?
Yes we offer guaranteed maximum wear part cost per tonne contracts based on your specific feed material analysis providing predictable longterm budgeting

What are your payment terms?
Standard commercial terms involve progress payments tied key milestones delivery acceptance Final payment due upon successful completion performance run

Do you offer operator training?
Comprehensive training is included covering safe operation routine maintenance troubleshooting conducted both at commissioning at your facility