1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your sand and gravel profit margins? Your processing plant faces relentless challenges: abrasive materials that rapidly degrade equipment, inconsistent feed material that bottlenecks production, and the constant pressure to meet specification while controlling energy consumption. How much revenue is lost each month to unscheduled maintenance on crushers and screens? What is the true cost of product inconsistency leading to rejected loads or price penalties? These operational hurdles demand a solution engineered for durability and precision. The right primary crushing equipment is not just a purchase; it is a strategic investment in plant reliability and longterm profitability.

2. PRODUCT OVERVIEW

The Jaw Crusher serves as the critical first stage in sand, gravel, and aggregate processing plants. Engineered for highcapacity primary reduction of quarried rock, river gravel, and demolition concrete, it transforms large feed material into manageable sizes for downstream screening and secondary crushing.

Operational Workflow:
1. Feed Intake: Runofquarry (ROQ) material is loaded into the vibrating grizzly feeder (VGF), which bypasses fines and directs oversize to the crusher.
2. Compression Crushing: Material enters the crushing chamber where a stationary jaw plate and a moving jaw plate create a powerful compressive force.
3. Size Reduction: The rock is fractured until small enough to pass through the adjustable gap at the bottom, known as the closed side setting (CSS).
4. Discharge: Crushed product is discharged onto the main plant conveyor for transport to subsequent processing stages.

Application Scope & Limitations:
Scope: Ideal for hard, abrasive materials like granite, trap rock, and abrasive gravels. Highly effective in stationary plants and portable crushing setups.
Limitations: Not suitable for sticky or highclay materials that may cause chamber packing. Maximum feed size is limited by the crusher's gape opening.

3. CORE FEATURES

HeavyDuty Frame & Welded Stress Relief | Technical Basis: Finite Element Analysis (FEA) optimized design with postweld heat treatment | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading, ensuring decades of structural integrity | ROI Impact: Reduces risk of catastrophic frame failure, protecting your core capital asset

Deep Crushing Chamber & Aggressive Toggle | Technical Basis: Enhanced nip angle and longer crushing zone geometry | Operational Benefit: Increases capacity per stroke and improves particle shape by promoting interparticle crushing | ROI Impact: Higher throughput of inspec product directly increases tonsperhour revenue

Hydraulic Toggle Adjustment System | Technical Basis: Integrated hydraulic ram replaces traditional mechanical shims | Operational Benefit: Allows operators to adjust the CSS safely in minutes for product size changes versus hours of downtime | ROI Impact: Minimizes nonrevenue generating downtime during changeovers, improving plant flexibility

QuarryGrade Jaw Dies & Cheek Plates | Technical Basis: Highstrength manganese steel alloy with optimized tooth profiles | Operational Benefit: Extended wear life in highly abrasive applications reduces changeout frequency | ROI Impact: Lowers costperton for wear parts and reduces labor hours dedicated to liner maintenance

Centralized Greasing Point & Accessible Design | Technical Basis: Lube lines routed to a single station with safetyguarded service points | Operational Benefit: Enables routine maintenance (greasing, inspections) to be performed quickly and safely without complex disassembly | ROI Impact: Promotes preventative maintenance adherence, preventing costly bearing failures and unplanned stops

VBelt Drive & Flywheel Momentum | Technical Basis: Robust flywheel design stores energy on the return stroke of the jaw | Operational Benefit: Smoothes power demand peaks, reducing stress on electric motors and drive components during crushing cycles | ROI Impact: Enhances electrical efficiency component longevity lowers longterm operating costs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Jaw Crusher Solution Documented Advantage |
| : | : | : |
| Wear Life of Jaw Dies (Abrasive Granite) | 120,000 150,000 tons per set Field data shows consistent wear life exceeding 180,000 tons per set Up to +20% improvement |
| CSS Adjustment Downtime (Mechanical vs. Hydraulic) ~46 hours for shim adjustment Documented average adjustment time of 3045 minutes Approx. 85% time reduction |
| Power Consumption (kWh per ton) Varies by material; baseline established Our models demonstrate up to an 8% reduction through chamber geometry & drive efficiency Up to 8% improvement |
| Uptime Availability (Annual Target) Industry target ~9294% Designed for >95% availability through reliability engineering +23 percentage points |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 200 1,600 metric tons per hour (MTPH), depending on feed material and closed side setting.
Feed Opening (Gape): Ranges from 800mm x 500mm (32" x 20") to 1,500mm x 1,200mm (59" x 47").
Power Requirements: Electric motor drive from 75 kW (100 HP) to 300 kW (400 HP). All motors are NEMA premium efficiency rated.
Material Specifications: Fabricated main frame from highgrade steel plate; jaw dies from premium manganese steel (14%,18%,22% Mn); spherical roller bearings rated for heavy shock loads.
Physical Dimensions & Weight: Varies by model; approximate footprint range from 3m x 2m up to 6m x 5m. Weights range from ~15,000 kg to over 70,000 kg.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C (13°F to +113°F). Dust sealing kits are standard for harsh environments.

6. APPLICATION SCENARIOS

LargeScale Granite Quarry Operation Challenge:

Excessive downtime for jaw die changes every six weeks was bottlenecking primary production at a major aggregate producer’s flagship site.

Solution:

Implementation of our heavyduty jaw crusher with proprietary jaw die profile metallurgy.

Results:

Wear life extended by approximately three weeks per cycle achieving over +22% more tons between changes This shift allowed alignment with quarterly maintenance schedules reducing annual planned stops by two full days

Portable Contract Crushing Business Challenge:

A mobile crushing contractor needed faster setup teardown times between diverse job sites including varying final product specifications requiring frequent CSS adjustments

Solution:

Deployment of our portable jaw crusher plant featuring the hydraulic toggle adjustment system

Results:

CSS changeover time reduced from an average of four hours using manual shims to under forty minutes This enabled the contractor bid on more jobs requiring specific products increasing annual contract revenue by an estimated %

7 COMMERCIAL CONSIDERATIONS

Our jaw crushers are offered in three primary tiers:

Standard Duty Tier: For consistent lessabrasive materials Competitive pricing focused on essential reliability
HeavyDuty Tier (Recommended for Sand Gravel Mining): Includes all features listed above such as hydraulic toggle premium dies stressrelieved frame The optimal balance of performance durability
SuperDuty Tier: For extreme abrasion or very high tonnage applications Includes additional reinforcement specialized alloys

Optional features include automated lubrication systems motor starters variable frequency drives VFDs extended warranty packages Service agreements are available covering everything from scheduled inspections parts supply guaranteed response times Financing options include capital lease operating lease or loan structures tailored typical equipment lifecycle

8 FAQ

What is maximum recommended feed size for your jaw crushers
Feed size should not exceed % of the crusher’s gape width dimension measured top between jaws Specific guidance provided each model ensure optimal performance prevent bridging

Can these crushers handle recycled concrete asphalt RAP
Yes they are wellsuited processing demolition concrete clean rubble Asphalt RAP can processed but requires careful evaluation potential gumminess may recommend specific tooth profiles chamber cleaning options

How does hydraulic toggle system improve safety
It eliminates need personnel use manual tools pry bars insert heavy shims confined dangerous space around toggle area All adjustments performed remotely control station significantly reducing injury risk

What typical delivery lead time after order placement
For standard heavyduty models lead time averages weeks Custom configurations superduty units may require longer lead times detailed project schedule provided upon application review

Do you offer performance guarantees
Yes we provide guaranteed minimum capacity wear rates based your specific feed material analysis These are formalized purchase agreement following laboratory testing sample material