1. PAINPOINT DRIVEN OPENING

Are you managing unpredictable production bottlenecks and rising operational costs in your aggregate or mineral processing plant? Key challenges with secondary and tertiary crushing often include:

High Wear Part Costs & Unplanned Downtime: Frequent replacement of hammers, liners, and blow bars due to abrasive materials, leading to significant parts expenditure and production halts.
Inconsistent Product Gradation: Fluctuations in feed material density or composition can cause unwanted fines or oversized product, failing to meet strict specification requirements for downstream processes or final product sales.
Excessive Energy Consumption: Older or inefficient impact crusher designs consume disproportionate power per ton of processed material, directly impacting your bottomline operating costs.
Limited Application Flexibility: A crusher that cannot be adjusted efficiently for different product sizes or material types forces operational compromises and limits plant versatility.

Is there a solution that delivers consistent product shape, reduces total cost of ownership through superior wear management, and provides the operational flexibility modern operations demand?

2. PRODUCT OVERVIEW: HIGHPERFORMANCE EXPORT IMPACT CRUSHERS

Our line of exportready horizontal shaft impact (HSI) crushers is engineered for highvolume reduction of medium to lowabrasive materials such as limestone, recycled concrete, asphalt, and demolition debris. These machines are central to aggregate production and recycling operations.

Operational Workflow:
1. Feed Entry: Material is directed into the robust feed hopper and onto the adjustable feed chute.
2. Acceleration & Impact: Material is struck by highvelocity rotating hammers (blow bars) mounted on a solid rotor assembly and hurled against the adjustable primary impact aprons (curtains).
3. Controlled Reduction: Size reduction occurs through both initial impact and subsequent collisions between particles (rockonrock crushing within the chamber).
4. Product Ejection & Sizing: Crushed material exits through the adjustable gap between the rotor and the aprons. A secondary apron/cage may be used for further refinement before discharge onto a conveyor.

Application Scope & Limitations:
Ideal For: Limestone, dolomite, recycled concrete/asphalt (RAP/RAS), sand & gravel, coal, and similar materials with low to medium silica content.
Limitations: Not recommended for highly abrasive materials (e.g., granite, trap rock, quartzite) as primary reduction units due to accelerated wear rates; these are better served by primary jaw or cone crushers.

3. CORE FEATURES

Hydraulic Adjustment System | Technical Basis: Computercontrolled hydraulic cylinders | Operational Benefit: Allows operators to adjust the primary apron setting during operation for realtime product size control without stopping production. | ROI Impact: Reduces adjustment downtime by up to 90%, increasing annual throughput capacity.

Modular Wear Component Design | Technical Basis: Segmented wear plates and reversible/rotatable blow bars | Operational Benefit: Enables partial replacement of worn sections and extends component life by utilizing multiple edges. Reduces maintenance time through simpler handling. | ROI Impact: Lowers wear part inventory costs by 2540% and reduces labor hours per changeout by an estimated 30%.

Solid Rotor vs. Open Disc Design | Technical Basis: Fabricated steel rotor with monolithic structure | Operational Benefit: Provides superior inertia for crushing larger feed sizes and higher durability with fewer stress points compared to open disc rotors. Essential for heavyduty applications. | ROI Impact: Increases mean time between failures (MTBF) for the rotor assembly, reducing major overhaul frequency and associated capital repair costs.

Advanced Chamber Geometry | Technical Basis: Optimized internal profiles derived from computational fluid dynamics (CFD) analysis | Operational Benefit: Improves material flow through the crushing chamber, reducing recirculation load and power surges while enhancing particleonparticle breakage for better cubicity. | ROI Impact: Achieves up to a 15% improvement in energy efficiency (kWh/ton) compared to previousgeneration designs.

QuickAccess Maintenance Doors | Technical Basis: Large, hinged service doors with safety lockout provisions | Operational Benefit: Provides safe, direct access to the interior chamber for inspection, blow bar rotation/replacement, and apron adjustment without major disassembly. | ROI Impact: Cuts standard service intervals from hours to minutes directly translating to higher plant availability.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Export Impact Crusher Solution | Documented Advantage |
| : | : | : | : |
| Wear Cost per Ton (Limestone) | $0.022 $0.035/ton | $0.016 $0.025/ton | Up to 30% Reduction |
| Power Consumption (kW per 100 tph) ~250 kW / 100tph ~215 kW / 100tph ~14% Improvement in Efficiency |
| Product Cubicity Index (>20mm fraction) CI of 0.75 0.85 CI consistently >0 .88 Improved Aggregate Shape |
| Average Time for Apron Gap Adjustment Manual shim adjustment (~48 hrs) Hydraulic system (~2030 mins) ~90% Faster Adjustment |

5.TECHNICAL SPECIFICATIONS

Capacity Range: Models available from 150 to 800+ tonnes per hour (TPH), depending on feed material density and product size setting.
Rotor Diameter & Width: From Ø1300mm x 1200mm up to Ø2000mm x 2500mm configurations.
Drive Power Options: Electric motor drives ranging from 250 kW to 800 kW , tailored to regional voltage standards (e.g.,50Hz /60Hz ,400V ,6 .6kV).
Feed Opening Size: Up t o1600mm x2500 mm maximum feed size capability .
Key Material Specifications :
Rotor Shaft :Forged42CrMo steel ,ultrasonically tested .
Housing : Fabricatedfromhigh yieldstrengthsteelplatewithinternalbolt onwearliners .
Blow Bars : Premium chromium ceramic composite alloys or martensitic steel options available .
Operating Temperature Range : Designedforambientoperationfrom20°Cto+45°Cwithappropriate lubrication systems .

6 .APPLICATION SCENARIOS

Aggregate Quarry Expansion Challenge A Midwest US limestone quarry needed t oincrease minus 1”baseproductproductionwithoutaddinganewcrushinglineorbudgetforfrequentdowntime .Solution Installationofahigh capacityexportimpactcrusherasasecondaryunitpost jawcrusher ,utilizingitshydraulicadjustmenttoshiftbetween1”and¾”productasneeded .Results Theplantachieveda22 %increaseinbaseproductthroughput .Wearcostsremainedstable despitehighertonnage ,andoperatorscouldmeetchangingdailyorderspecificationsinunderanhour .

Construction &Demolition(C&D )RecyclingFacility Challenge AnurbanC&Drecyclerfacedexcessivewearandunacceptablemetalliccontamination( rebar )intheirfinalaggregateproductfromanolderimpactcrusher .Solution Implementationofasolid rotorexportimpactcrusherequippedwithspecializedblowbarsto handlehighshockloadsandembeddedmetal .Thedesignincludedamagneticseparationconveyorpost crush .Results Contaminationinminus ¾”recycledaggregatefellbelow1 %byweight ,meetingstrictspecificationsfordrainageapplications .Blowbarlifeincreasedbyapproximately60 %despitetheabrasiveandunpredictablefeed .

7.COMMERCIAL CONSIDERATIONS

Our export impact crushers are offered in three primary tiers :

Standard Duty Series : Forconsistent ,medium abrasivematerials(likepurelimestone ).Focusesoncore reliabilityandcapitalcostoptimization .
Heavy Duty Series : Fortougherapplicationsincludingrecycledconcretewithhighercontaminantlevels .Featuresreinforcedcomponentsandsolidrotortechnologyasstandard .
Modular Plant Series : Fullyintegratedskid mountedorsemi portableunitspre wiredandpipedforrapiddeployment ;includespresetfeedersandscreens .

Optional features include automatedgreasingsystems ,vibrationmonitoringpackages ,specializedwearlinermaterials( e.g.,ceramicinserts ),andenclosedwalkwaysforservice .

We offercomprehensiveservicepackagesfrombasiccommissioningtofullannualmaintenanceagreementswithguaranteedresponse times .Financingandleasingoptionsareavailablethroughpartnersto managedeploymentcapital .

8.FAQ

Q1:Arewearpartsinterchangeablewithotherbrandsofcrushers ?
A1 No Ourexportimpactcrushersaredesignedwithproprietarymodularwearcomponentsforsuperiorperformanceandspecificbalancingrequirements Weguaranteeoptimalperformanceonlywithourgenuineparts

Q2:Whatisthetypicalleadtimeforreplacementrotorsor majorshaftcomponents ?
A2 Forcriticalcomponentslikerotors we maintain strategic inventory of key sub assemblies Lead times vary but we target shipment of major components within46weekswithemergencysupportoptionsavailable

Q3:Canyourimpactcrusherhandleaclosedcircuitoperationwithareturnfeed( recirculatingload)?
A3 Yes allmodelsaredesignedforthedemandsofclosedcircuitoperations Thesolidrotordesignprovidesthenecessaryinertiaandthehydraulicsystemallowsquickcompensationforchangesinchamberload

Q4:Doyouprovideperformanceguarantees ?
A4 Yes weoffercontractualguaranteesforcapacity throughput basedonagreedfeedmaterialanalysis aswellasmaximumwearratesforblowbarsandlinersunderdefinedoperatingconditions

Q5:Whattrainingisprovidedforouroperatorsandmaintenancestaff ?
A5 Weincludecomprehensiveonsiteoperator trainingduringcommissioning coveringnormaloperation adjustmentsafetyprotocolsanddailychecks Indepthmaintenancetrainingfocusedonwearpartreplacementandsystemdiagnosticsisalsoavailable

Q6:Iscustomizationavailablefordifferentvoltageorpowersupplyrequirements ?
A6 Absolutely Asanexport specialist weengineereachunittomeetthedestinationcountry’sspecificpowerstandards includingmotors startersandcontrolpanelconfigurations

Q7 Howdoesthecostofownershipcomparetoaconecrusherforsimilarapplications ?
A7 Forlowto mediumabrasivematerials anexportimpactcrusheroffersalowerinitialcapitalinvestment significantlylowerwearcostspertonneproducesamorecubicalproduct butmayhavehigherwearcostsinhighlyabrasiveapplicationscomparedtoacone OurteamcanprovideadetailedTCOanalysisbasedonyourspecificmaterial