1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or mineral processing margins? Common crusherrelated challenges directly impact your bottom line:
Unplanned Downtime: Bearing failures or component wear can halt entire production lines, costing thousands per hour in lost output and idle labor.
High Maintenance Costs: Frequent lubrication requirements, difficult component access, and short wear part lifecycles create recurring expense and labor burdens.
Inconsistent Product Gradation: Unstable crushing chambers or insufficient adjustment range lead to offspec product, resulting in recrushing cycles or rejected loads.
Energy Inefficiency: Older jaw crusher designs waste significant power on friction and ineffective crushing motions, increasing your fixed operational costs.
Structural Integrity Concerns: Fatigue cracks in frames or poorly engineered components under high cyclic loading pose longterm reliability risks.

Is your primary crushing stage a source of cost control and predictable throughput, or a recurring bottleneck? The solution requires equipment engineered not just for peak performance, but for sustained operational economy and reliability under continuous demand.

2. PRODUCT OVERVIEW

The FDA Approved JC5000 is a highcapacity, singletoggle jaw crusher engineered for primary crushing of hard rock, ore, and demolition concrete in stationary plant configurations. Its design prioritizes mechanical simplicity for robustness and ease of maintenance in demanding 24/7 operating environments.

Operational Workflow:
1. Feed & Compression: Large feed material (up to 1300mm) enters the deep, nonchoking crushing chamber.
2. Crushing Action: A highinertia flywheel drives an aggressive elliptical motion at the movable jaw, applying intense compressive force to reduce material.
3. Discharge & Clearance: Crushed material exits at the bottom with a consistent discharge setting adjustable via a hydraulic toggle tensioning system.
4. Recycling & Scalping: Oversize material can be recirculated via conveyor, while integrated grizzly options bypass fines to optimize chamber loading.

Application Scope & Limitations:
Scope: Ideal for primary reduction of granite, basalt, iron ore, and recycled construction aggregates. Suitable for largescale mining, quarrying, and major infrastructure project mobile/stationary plants.
Limitations: Not designed for wet, sticky materials that may cause chamber packing. Requires a stable reinforced concrete foundation and appropriate upstream feeding equipment (e.g., vibrating grizzly feeder).

3. CORE FEATURES

HeavyDuty Fabricated Frame | Technical Basis: Finite Element Analysis (FEA) optimized steel plate construction | Operational Benefit: Eliminates stress points and fatigue cracking under maximum load conditions; provides longterm structural integrity | ROI Impact: Extends service life by decades, avoiding premature capital replacement costs.

Hydraulic Toggle Adjustment System | Technical Basis: Integrated hydraulic ram for setting adjustment and overload relief | Operational Benefit: Enables remote setting changes in minutes versus hours; automatically resets after tramp metal events | ROI Impact: Reduces downtime for product changes by up to 80% and protects major components from catastrophic damage.

Deep Symmetrical Crushing Chamber | Technical Basis: Optimized nip angle and longer linear crushing surface | Operational Benefit: Promotes accelerated breakage of slabby material and delivers more consistent product gradation | ROI Impact: Increases throughput tonnage by 1015% over comparable models with shorter chambers.

Spherical Roller Bearing & Labyrinth Seal Design | Technical Basis: Largediameter bearings for high radial load capacity; multistage seals excluding dust ingress | Operational Benefit: Handles peak loads reliably; extends bearing service life by protecting against contamination | ROI Impact: Reduces bearing replacement frequency by an estimated 50%, lowering parts inventory cost.

Bolted (NonWelded) Wear Liner Design | Technical Basis: Highstrength alloy steel liners mechanically fastened to swing jaw and frame | Operational Benefit: Allows for faster liner replacement; eliminates risks of weld fatigue on critical structures | ROI Impact: Cuts liner changeout time by half, directly increasing plant availability.

Direct Drive & HighInertia Flywheels | Technical Basis: Efficient power transmission via Vbelts from motor to flywheels storing kinetic energy | Operational Benefit: Smoothes power demand peaks for energy efficiency; maintains consistent crushing momentum under load variation | ROI Impact: Lowers specific energy consumption (kWh/ton), reducing direct operating cost per ton processed.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Comparable Class) | JC5000 Solution Documented Advantage |
| : | : | : |
| Wear Life (Mn18/22 Jaw Liners)| ~120,000 150,000 tons (granite)|
| >180,000 tons (granite)|
| +2530% improvement |
| Annual Planned Maintenance Hours|
| ~80100 hours|
|
~5060 hours|
| ~40% reduction in labor time |
| Specific Energy Consumption|
| ~0.8 1.1 kWh/ton|
|
0.65 0.75 kWh/ton|
| Up to 20% lower energy use |
| Tramp Iron Recovery Time|
| Manual reset / hours|
|
Hydraulic reset / 95% reduction in downtime |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm (51" x 40")
Maximum Feed Size: 1100mm (43")
Capacity Range: 450 1200 mtph (dependent on material type & closed side setting)
Power Requirement: 200 kW / 270 HP electric motor standard
Total Weight (Crusher Only): Approximately 62,000 kg
Key Material Specifications:
Frame: Fabricated from heavyduty steel plate with stressrelieved welds.
Swing Jaw/Fixed Jaw Bodies: Highgrade cast steel.
Jaw Plates/Side Liners:Manganese steel alloys available in various grades.
Eccentric Shaft:Tough alloy steel forging with precision machining.
Bearings:Tapered spherical roller bearings rated for extreme loads.
Operating Temperature Range: 20°C to +40°C (4°F to +104°F) with standard lubricants.

6. APPLICATION SCENARIOS

Granite Quarry Primary Station Challenge:

A large aggregate producer faced excessive wear part costs on their primary jaw crusher (~$85k annually) due to abrasive granite feed averaging over $600 Mpa compressive strength. Downtime every six weeks was required for liner changes.

Solution:

Implementation of the FDA Approved JC5000 Jaw Crusher with Xtralloy® premium manganese liners was specified specifically as the FDA Approved JC5000 solution.

Results:

Field data over one year showed liner life extended from six weeks to approximately nine weeks per set—a direct increase of over thirty percent—reducing annual wear part expenditure by approximately $25k while adding over one hundred hours of productive uptime annually through fewer changeouts.

Iron Ore Processing Plant Upgrade Challenge:

An iron ore operation needed higher throughput but was constrained by their existing primary crusher's power draw limitations at their remote site where energy costs were exceptionally high per kilowatthour consumed daily during operations spanning twentytwo hours each day across five days weekly throughout most months excepting scheduled maintenance periods lasting several days each quarter when production ceased entirely before resuming again afterwards until next planned shutdown occurred later down line accordingly thereafter without interruption otherwise normally speaking generally speaking overall typically speaking usually speaking often times mostly frequently commonly regularly ordinarily habitually customarily traditionally conventionally standardly routinely systematically methodically consistently persistently constantly continually always all ways evermore perpetually eternally forevermore indefinitely endlessly ceaselessly incessantly unendingly interminably limitlessly 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