1. PAINPOINT DRIVEN OPENING

Are you facing escalating operational costs and unpredictable availability in your primary crushing circuit? Key challenges with primary gyratory crushers often include:
Unscheduled Downtime: Frequent mechanical failures or liner changes that halt upstream mining and downstream processing, costing thousands per hour in lost production.
High Maintenance Costs: Excessive consumption of wear parts, complex lubrication system issues, and laborintensive servicing that strain maintenance budgets.
Inconsistent Throughput: Inability to maintain optimal cavity levels and power draw, leading to bottlenecks and failing to meet designed plant capacity.
Rising Energy Expenditure: Older, inefficient crusher designs consume disproportionate power per ton of processed material, directly impacting your bottom line.

Is your current primary crusher a reliable asset or a constant source of risk? The solution lies in selecting a modern OEM gyratory crusher engineered for total cost of ownership.

2. PRODUCT OVERVIEW

The OEM Gyratory Crusher is a heavyduty, primary compression crusher designed for the first stage of reducing runofmine ore to a manageable size for conveying and further processing. Its core operational workflow involves:
1. Feed Intake: Large feed material is directed into the crushing chamber from the top.
2. Compressive Crushing: A mantle gyrates within a concave bowl, applying compressive force to reduce material by squeezing it against the stationary concaves.
3. Progressive Discharge: Crushed material gravitates downward through the narrowing chamber until it reaches the desired size and exits at the bottom.

This equipment is specifically scoped for hightonnage, hard rock mining (copper, iron ore, gold) and largescale aggregate quarrying applications. It is not suited for abrasive recycling materials without specific alloy options or for operations requiring highly portable equipment.

3. CORE FEATURES

Patented Spider Design | Technical Basis: Onepiece cast alloy steel construction with top shell integration | Operational Benefit: Eliminates bolton spider arms, reducing stress points and potential for cracking under extreme load | ROI Impact: Up to 40% longer service life on upper assembly components, reducing major rebuild frequency.

Intelligent Lube System (ILS) | Technical Basis: Automated, dualcircuit lubrication with realtime pressure/temperature monitoring and filtration | Operational Benefit: Ensures optimal bearing protection under all loads; alerts operators to potential issues before failure | ROI Impact: Proven to extend bearing life by over 30% and prevent catastrophic luberelated downtime events.

STLF (StraightTaperLowerFlat) Concave Profile | Technical Basis: Optimized chamber geometry derived from crushability testing data | Operational Benefit: Maintains consistent feed opening characteristics throughout liner life for stable throughput and product gradation | ROI Impact: Delivers up to 15% more crushed tonnage per concave liner set compared to traditional profiles.

Tubular Frame & Mainshaft Design | Technical Basis: Forged highstrength steel mainshaft supported within a rigid, onepiece tubular frame | Operational Benefit: Provides exceptional alignment stability and resists fatigue under cyclical loading for consistent operation | ROI Impact: Minimizes deflectionrelated wear on bushings and liners, lowering longterm maintenance costs.

Integrated Control System (ICS) Interface | Technical Basis: Standardized PLC platform with MODBUS/J1939 protocols for plantwide integration | Operational Benefit: Your operators gain realtime control over CSS (Closed Side Setting), power draw, and lubrication from the central control room | ROI Impact: Enables precise process optimization for energy savings and target product size.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | OEM Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled) | 92 94% | 96%+ (with ILS & Patented Spider) | +24% |
| Tons per MWh (Energy Efficiency) Baseline = 100%| 100% Reference| 115 118%| +1518% |
| Liner ChangeOut Time (Major Set) Average = ~48 hrs| ~48 hours| ~36 hours| 25% |
| Wear Part Consumption (g/ton crushed) Material Dependent Baseline = 100%| 100% Reference| ~8590%| 10 to 15% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent, from 2,000 tph to over 10,000 tph.
Motor Power: Typically between 450 kW and 1,200 kW (600 HP 1,600 HP), tailored to duty.
Feed Opening: Gape sizes from 1,000 mm to 1,500 mm (39" to 59").
Key Material Specifications:
Main Frame & Top Shell: Hightensile cast steel.
Mantle & Concaves: Manganese steel alloys; optional premium alloys for specific abrasion/corrosion applications available.
Mainshaft: Forged highstrength alloy steel.
Physical Dimensions: Significant footprint; exact L x W x H varies by model. Requires engineered reinforced concrete foundation.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C (40°F to +122°F). Dust seals rated for harsh environments.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: An existing mine’s expansion required a new primary crushing station capable of handling an additional 12 million tpy of sulfide ore while operating at >95% availability in a remote location with high service costs.
Solution: Installation of a single largecapacity OEM Gyratory Crusher with the Intelligent Lube System (ILS) and remote monitoring capabilities.
Results: Achieved design throughput within three months of commissioning. The ILS prevented two potential bearing failures in the first two years as flagged by its monitoring system. Availability averaged 96.7% over three years.

HighAbrasion Granite Quarry

Challenge A major aggregate producer faced unsustainable wear part costs and excessive downtime due to biweekly concave changes in their primary crushing stage.
Solution Replacement with an OEM Gyratory Crusher featuring the STLF concave profile and optional ultrawearresistant alloy liners specified for granite.
Results Liner service life increased from an average of 14 days to 21 days. This reduced annual scheduled liner change downtime by approximately 120 hours, while also lowering liner cost per ton by an estimated 18%.

7. COMMERCIAL CONSIDERATIONS

OEM Gyratory Crushers are capital investments priced according to size, capacity specifications (<tph), selected metallurgy options (<alloy grade), level of automation (<control package). Pricing typically falls into distinct tiers based on inlet size (<42”, <54”, <60”+).

Optional features that affect final pricing include:
Automated Setting Regulation () system
Premium alloy packages for mantles/concaves
Advanced condition monitoring sensors (, temperature)
Extended factory warranty packages

Comprehensive service agreements are available covering planned maintenance inspections parts supply (, bearings), technical support These agreements can be structured as fixedcost annual contracts providing budget certainty Financing options including leasing capital equipment loans are offered through certified partners

8. FAQ

Q What are the lead times typically involved?
A Lead times vary based on model complexity current manufacturing capacity but generally range from

Q Can this crusher integrate with our existing PLC control system?
A Yes The Integrated Control System uses industrystandard communication protocols like MODBUS TCP/IP ensuring compatibility with most modern plant DCS systems

Q How does this design improve safety during maintenance?
A Key safety features include hydraulic setting adjustment eliminating manual work under tension integrated lifting points designed rigging procedures provided

Q What is included in standard commissioning?
A Standard commissioning includes field assembly supervision initial startup performance testing operator training Documentation includes detailed installation maintenance manuals

Q Are performance guarantees provided?
A Yes performance guarantees covering throughput power consumption product gradation are contractually defined based on agreed feed material characteristics