1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your quarry's profitability? For plant managers and engineering contractors, ballast production presents distinct challenges that directly impact the bottom line. Common pain points include:
Excessive Fines Generation: Up to 1520% of processed material can fall below spec, turning potential revenue into waste stockpiles.
High Wear Part Consumption: The abrasive nature of trap rock, granite, and basalt leads to premature liner and hammer failure, causing frequent, costly maintenance stops.
Inconsistent Product Cubicity: Poor particle shape in the final product reduces track bed stability and can lead to product rejection.
Energy Inefficiency: Older crushing stages consume disproportionate power for the usable tonnage produced, inflating operational expenses.
Inflexible Capacity: Fixed plants struggle to adapt to fluctuating demand, creating bottlenecks or underutilization.

Is your current setup equipped to maximize yield from every ton of feed while controlling maintenance costs and energy consumption? The right primary crushing equipment is the foundational answer.

2. PRODUCT OVERVIEW: ODM QUARRY PRIMARY JAW CRUSHER FOR BALLAST PRODUCTION

This product line focuses on heavyduty primary jaw crushers engineered specifically for highvolume ballast production from hard, abrasive feed materials. As an ODM (Original Design Manufacturer), we provide customized crushing solutions built to your precise operational parameters and site constraints.

Operational Workflow:
1. Primary Reduction: ROM (RunofMine) quarry rock, typically up to 800mm in size, is fed into the crusher's robust vibrating grizzly feeder (VGF) section.
2. PreScreening & Crushing: The VGF removes natural fines and bypasses subsize material, directing only oversize rock into the crushing chamber. The deep,symmetrical jaw chamber performs the initial compressive break.
3. Product Shaping: The kinematics of the jaw plate motion are optimized to promote interparticle crushing, enhancing particle cubicity on the first pass.
4. Discharge & Conveyance: Crushed material is discharged at a consistent CSS (Closed Side Setting) onto the primary conveyor for transport to secondary screening and crushing stages.

Application Scope & Limitations:
Ideal For: Primary crushing of hard, abrasive igneous rock (granite, basalt) and dense limestone for railway ballast and construction aggregates.
Limitations: Not suitable for sticky, claybound materials without prescreening/scalping. Feed size is constrained by crusher model inlet dimensions.

3. CORE FEATURES

HeavyDuty Rolled Steel Frame | Technical Basis: Singlepiece, stressrelieved fabrication | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading; provides stable platform for precision bearing alignment | ROI Impact: Extended structural life exceeding 20+ years reduces capital replacement risk.

Optimized Chamber Geometry & Kinematics | Technical Basis: ST/DT (Steep/Deeper Toggle) cavity design with aggressive nip angle | Operational Benefit: Increases throughput by up to 10% at same power draw; promotes better particle shape for downstream processing | ROI Impact: Higher yield of inspec product per operating hour directly increases revenue.

Hydroset CSS Adjustment System | Technical Basis: Hydraulic cylinders support the toggle seat for safe setting adjustment | Operational Benefit: Closedside setting changes can be made in minutes under load or during clearing strokes, without manual shims | ROI Impact: Reduces downtime for product size changes by over 80%, enhancing plant flexibility.

LongLasting Manganese Jaws with Clamp Systems | Technical Basis: Isovitric supergrade manganese steel with reversible design; mechanical clamp system for fast replacement | Operational Benefit: Jaw life increased by 2530%; changeout time reduced from days to a single shift | ROI Impact: Lowers costperton for wear parts and significantly increases plant availability.

Integrated PreScreening Grizzly Feeder | Technical Basis: Boltin grizzly sections with adjustable slope and gap settings | Operational Benefit: Removes up to 20% of fines prior to crushing chamber, reducing unnecessary wear and improving chamber efficiency | ROI Impact: Directly lowers wear part consumption and power cost per ton of crushed material.

Centralized Automated Greasing System | Technical Basis: Programmable lubrication unit serving all key bearing points | Operational Benefit: Ensures optimal bearing lubrication intervals; prevents both under and overgreasing failures | ROI Impact: Extends critical bearing service life by an average of 35%, preventing catastrophic downtime.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | ODM Quarry Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | ~8590% (scheduled & unscheduled stops) |> 94% (based on field monitoring data) |> +5% Improvement |
| Wear Cost per Ton (Abrasive Rock) $0.12 $0.18/ton| 25% Reduction |
| Specific Power Consumption| Varies widely; older units > 0.8 kWh/ton @ CSS 150mm| 19% Reduction |
| Fines Generation (<22mm)| ~1822% of total feed| 30% Reduction |
| Product Flakiness Index (Target 30% after primary stage| Consistently Improved Shape |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 400 1,800 tonnes per hour (TPH), depending on feed material and closedside setting.
Feed Opening: From 1,000mm x 650mm up to 1,500mm x 1,200mm.
Power Requirements: Drive motor from 90 kW up to 300 kW; total installed power including feeder hydraulics specified per model.
Material Specifications: Highstrength welded frame (S355JR steel); Isovitric manganese crusher jaws; forged alloy steel eccentric shaft with largediameter spherical roller bearings.
Physical Dimensions & Weight: Approximate weights from 35 tonnes to 120 tonnes; detailed layout drawings provided for foundation planning.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust sealing compliant with ISO standard levels; noise emissions designed below 105 dB(A) at operator stations.

6. APPLICATION SCENARIOS

Hard Rock Quarry Supplying National Rail Project

Challenge: A granite quarry needed to supply over 2 million tons of Type I ballast within a strict timeline but faced excessive wear costs and fines generation (>22%) from their existing primary crusher.
Solution: Implementation of a customconfigured ODM heavyduty jaw crusher with an integrated aggressive grizzly feeder profile optimized for their specific granite blend.
Results: Fines generation reduced to below spec at <14%. Wear part lifecycle extended by approximately28%. The project was completed ahead of schedule due to sustained throughput rates averaging12% above target.

Aggregate Producer Expanding into Rail Ballast Market

Challenge: An established aggregate producer lacked a primary stage capable of producing the consistent cubicity required by rail authorities without excessive secondary recrushing.
Solution: Installation of an ODM jaw crusher with a specially engineered chamber profile focused on firstpass shape optimization.
Results: Final product Flakiness Index achieved directly after primary crushing met rail specification (<25%), reducing load on secondary cone crushers by approximately15%. This allowed reallocation of secondary capacityto other product lines.

7. COMMERCIAL CONSIDERATIONS

Our ODM approach provides structured commercial flexibility:

Equipment Pricing Tiers: Based on model size/capacity range:
Tier I (1200 TPH): Fully customized solutions with advanced monitoring packages included.

Optional Features & Packages:
Advanced PLC automation package with loadregulation logic
Wear part monitoring sensors
Dust suppression system integration
Modular skidbase design for faster installation

Service Packages:
Basic Warranty Package
Comprehensive Service Agreement including scheduled inspectionsand parts discounts
Turnkey Installation & Commissioning Support

Financing Options:
We work with international export credit agenciesand equipment financing partners t o offer leasetoown arrangements , mediumterm loans , or tailored rentalpurchase agreements t o align w ith your project cash flow .

8.FAQ

Q:What level o f customization i s possible w ith your ODM jaw crushers?
A.We can modify several parameters including feeder dimensions ,grizzly bar configuration ,discharge conveyor interface points ,and motor mounting positions t o ensure compatibility w ith your existing plant layoutand feed system .

Q.How does this equipment improve our overall plant efficiency beyond justtheprimary stage?
A.B y deliveringa more consistent ,cubicalproductatthefirststage,yoursecondaryand tertiarycrushers operate more efficiently .This reduces circulating loadsand improves finalproductyieldwhile loweringtotalplantpowerconsumption .

Q:What i sthetypical delivery lead timeforacustomized unit?
A.Forstandardmodels withinourTierI&IIrange ,lead timesaretypically1622weeksfromorderconfirmation .FullycustomizedTier IIIsolutionsrequire detailed engineeringand mayextendto28weeks .Proactive planningi srecommended .

Q.Arewearparts interchangeablewithothercrusherbrands?
A.No .Ourwearpartsaredesigned specificallyforourchambergeometryandkinematics t oensureoptimalperformanceand longevity .We providecomplete technicaldrawingsforinventory planning .

Q.What kindo f foundationi srequired ?
A.We providecomprehensivefoundationdrawingswitheachorderincludingallstaticand dynamicloaddata .Foundationsaretypicallyreinforcedconcrete ;our engineerscanreviewyoursitespecificplansuponrequest .

Q.Doyouoffertrainingforouroperatorsandmaintenancestaff ?
A.Y es.O nsiteoperationalandsafetytrainingduringcommissioningi sincludedwith everysale .Additionalmaintenancetrainingmodulesareavailableaspartofourservicepackages .

Q.Whatarethekeyfactorsin determiningthecorrectmodelsizeforourapplication ?
A.Capacityselectionisbasedonfourprimaryfactors :yourmaximumfeedsizematerialhardnessorBWI( BondWorkIndex ),desiredproductsize( CSS ),andrequiredhourlytonnage .Ourtechnicalteamwillanalyze yoursamplesandspecificationst orecommendtheoptimalmodel