1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the secondary crushing stage is a critical bottleneck where inefficiencies translate directly to lost revenue. Common challenges with conventional impact crushers include:
Excessive Wear Part Costs: Premature failure of blow bars and wear liners due to inconsistent feed material or suboptimal impact dynamics, leading to frequent, costly shutdowns for replacement.
Unplanned Downtime for Maintenance: Difficult access to the crushing chamber and complex rotor service requirements extend routine maintenance from hours to days, idling your entire processing line.
Product Gradation Inconsistency: Uncontrolled particle velocity and poor chamber geometry result in an unpredictable product curve, forcing downstream adjustments and compromising final spec compliance.
High Energy Consumption per Ton: Inefficient transfer of energy from rotor to material, often exacerbated by outdated drive systems, inflates your most controllable operating expense.

What if your impact crushing operation could deliver higher throughput with lower costperton, while maintaining scheduled availability above 95%? The solution lies in a precisionengineered impact crusher designed not just to crush, but to optimize your entire circuit's financial performance.

2. PRODUCT OVERVIEW: HEAVYDUTY SECONDARY IMPACT CRUSHER

This equipment is a horizontal shaft impact (HSI) crusher engineered for highvolume reduction of limestone, recycled concrete, asphalt, and other mediumhard aggregates in stationary plant configurations. Its operational workflow is defined by controlled, highinertia impact:
1. Controlled Feed: Material is directed by a adjustable feed chute onto the rotating assembly.
2. HighVelocity Impact: Feed material is struck by massive manganesealloy blow bars mounted on a solid steel rotor, initiating fracture.
3. Accelerated Projection: Broken material is propelled into robust adjustable aprons or grinding path for secondary reduction.
4. Controlled Discharge: Sized product exits through hydraulically adjustable discharge opening, ensuring consistent gradation.

Application Scope: Ideal for secondary crushing duties following a primary jaw crusher, and for primary crushing of nonabrasive materials like limestone. Effective for recycling applications (concrete, asphalt).
Key Limitations: Not recommended for highly abrasive materials (e.g., some igneous rock) without accepting higher wear costs. Requires consistent feed size to maintain optimal performance and protect components.

3. CORE FEATURES

Hydraulic Adjustment System | Technical Basis: Integrated hydraulic cylinders controlling apron position | Operational Benefit: Allows operators to adjust product size or clear blockages in minutes from outside the machine | ROI Impact: Reduces adjustment downtime by up to 80% compared to manual shim systems.

Solid Rotor Construction | Technical Basis: Monobloc or welded steel rotor design with high mass index | Operational Benefit: Delieves greater kinetic energy to material for superior reduction ratios and handles larger feed sizes with less vibration | ROI Impact: Increases potential throughput by 1525% over lighterweight designs, improving circuit capacity.

MultiFunctional Crusher Housing | Technical Basis: Hydraulically opening frame with integrated service crane | Operational Benefit: Provides full, safe access to all internal wear parts and the rotor for inspection and maintenance | ROI Impact: Cuts major service time by half, translating to more tons processed between scheduled outages.

Advanced Wear Component Metallurgy | Technical Basis: Ceramic composite or highchrome martensitic steel blow bars & apron liners | Operational Benefit: Extends service life in abrasive applications by optimizing hardnesstoughness balance | ROI Impact: Field data shows a 3050% improvement in wear life over standard manganese steel in equivalent duty.

Direct Drive Transmission | Technical Basis: Vbelt or fluid coupling drive connecting motor directly to rotor | Operational Benefit: Eliminates gearbox maintenance, improves power transmission efficiency (>96%), and dampens shock loads | ROI Impact: Lowers lifetime operating costs through reduced component inventory and higher energy efficiency.

PLCBased Monitoring & Automation Interface | Technical Basis: Sensors for bearing temperature, vibration, rotor speed & hydraulic pressure linked to control panel | Operational Benefit: Enables predictive maintenance alerts and seamless integration into plantwide SCADA systems for optimized performance | ROI Impact Prevents catastrophic failures; allows datadriven planning that maximizes asset utilization.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution (Conventional HSI) | Our HeavyDuty Impact Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Life (Blow Bars)| Standard Manganese Steel / High Chrome Standard Castings| Proprietary Martensitic Alloy with Ceramic Inserts| +4060% Extended Life |
| Maintenance Access Time| Manual shimming; limited access points requiring partial disassembly| Full hydraulic housing opening; integrated lifting points| 50% Service Time |
| Energy Efficiency (kWh/ton)| Varies widely; older designs often exceed 0.81.2 kWh/ton at comparable reduction| Optimized chamber geometry & direct drive targets <0.7 kWh/ton| Up to 25% Energy Use |
| Availability (Scheduled)| ~9092%, factoring in longer mechanical adjustments & wear changes| Designed for >95%, via rapid adjustment & component access.| +35% Uptime |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 200 – 800+ TPH (dependent on feed material & product size)
Rotor Diameter & Width: 42” x 50” up to 64” x 80”
Drive Power Requirement: 300 HP – 800 HP (225 kW – 600 kW), electric motor
Max Feed Size: Up to 32” (800mm) edge length
Rotor Speed Range: Adjustable between 450 – 750 RPM
Key Material Specifications:
Rotor Body: ASTM A36 Steel / AR400 Steel
Blow Bars / Apron Liners: Martensitic Steel (Cr22), Manganese Steel (Mn18), or Ceramic Composite
Shaft Forging: HighTensile Alloy Steel
Bearing Housings: Cast ductile iron with spherical roller bearings
Physical Dimensions (Approx., Model Dependent): Length: ~12’, Width:~9’, Height:~10’
Operating Temperature Range: 20°C to +45°C (4°F to +113°F) with standard lubricants

6. APPLICATION SCENARIOS

Aggregate Producer Limestone Quarrying | Challenge A major quarry faced excessive downtime every 120 hours for blow bar rotation and replacement on their secondary impact crushers, bottlenecking their 600 TPH plant.| Solution Implementation of two heavyduty impact crushers featuring quickwedge locking systems for blow bars and hydraulic apron adjustment.| Results Blow bar changeout time reduced from 8 hours to under 2 hours per machine. Combined with extended wear life, crusher availability increased by 6%, yielding an additional ~35,000 tons of saleable product annually.

Construction & Demolition Recycling Contractor | Challenge Processing highly variable C&D feed resulted in frequent chamber blockages and erratic final product sizing at their urban recycling yard.| Solution A robust HSI crusher with a solid rotor design was selected specifically for its ability to handle large slabs of concrete rebar matting without stalling.| Results Blockage incidents fell by over . The consistent product gradation improved the marketability of their recycled aggregate base material increasing its sales price premium

Portable Crushing Contractor Challenge Their fleet of older mobile impactor plants suffered from high fuel consumption low reliability on remote job sites leadingto missed project deadlines Solution Deployment of new portable plants equippedwith modern efficient heavy duty impactors featuring direct driveand advanced wear packages Results Fuel consumption per ton crushed decreasedby an averageof . Machine reliability on critical infrastructure projects improved drastically reducing rental backup costs

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is structured around three primary tiers based on capacity robustnessand feature sets:

1 Entry Level Tier Designedfor lowerabrasion applications like pure limestone Includes core heavy dutyrotorand housingwith standard manganesewear parts Manual adjustment options Availablefrom $X

2 Performance Tier Our most common configuration Includes all core features listed above Hydraulic adjustment PLC monitoring premium martensiticsteelwearparts Recommendedfor mixedaggregateandrecycling Availablefrom $Y

3 Premium Custom Tier Engineeredfor maximum uptimein severe service Fully automated gap setting remote monitoring ceramic compositewearliners customfeed system integration Pricedon application basis

Optional Features Upgrades Include automatic greasing systems specialskid designs foreasier installation rock box undercrusher hoppers extendedwarranty packages

Service Support We offer tiered annual service agreements covering everythingfrom planned inspectionsand parts kits tomajor overhauls Financing throughpartner institutionsis availablefor qualified buyers covering both equipmentand installationcosts

8 FAQ

Q What primarycrusherfeed sizes are compatiblewithyour heavy dutyimpactcrushers A They are engineeredto accept directfeed fromjawcrushers setat6to8 typically handlingmaximumfeed sizesupto32 Consult oursizing guidefor specificcircuit pairing recommendations

Q How does thisimpactcrusherimprove my overallplantproduct quality A Consistent hydraulic apron control maintainsyour targetdischarge setting formore stableproductgradation This reducesloadon downstream screensand improvesyieldof inspecproductby minimizingrecirculation

Q Whatisthe typicallead timefor deliveryand installation A For standardPerformanceTier models leadtimeis approximately weeksuponorder confirmation Installationrequires dayswith preparedfoundationsby certifiedcrews Customconfigurationsvary

Q Arewearparts readilyavailableand interchangeablewithothermanufacturers A Wearparts are engineeredforspecificperformancein ourchambergeometry While dimensionalinterchange maybe possible itoften sacrificesupto ofthe designedwearlife We recommendgenuinepartsfor guaranteedperformance

Q Do youoffer financingor leasingoptions forequipmentacquisition A Yes we workwithseveralindustrial lendingpartners toofferflexiblefinancing solutionsincluding capital leases operatingleasesand loansto suitvarious balance sheetpreferences

Q Can existingplantcontrolsystems integratewiththe crushersPLC A The control systemis designedwithstandard communication protocols Modbus TCPIP typically allowingdirectintegrationinto mostmodernplantSCADA systemsfor centralizedmonitoringand control