1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? Plant managers and engineering contractors consistently face critical challenges in primary crushing operations: excessive wear part consumption from abrasive feed material, unplanned stoppages due to tramp metal or uncrushables, and inconsistent feed rates that create bottlenecks downstream. These issues directly translate to high maintenance labor costs, lost production hours, and compromised final product gradation.

What if your primary crusher could actively protect itself from damage? How would a 20% reduction in liner wear change your annual operating budget? Can your current setup maintain optimal throughput with varying feed sizes and hardness? The solution lies not just in a crusher, but in an integrated primary crushing station engineered for resilience and control.

2. PRODUCT OVERVIEW

The APC Series Primary Jaw Crusher Station is a heavyduty, fixedplant solution designed for the first reduction of hard rock and ores. This turnkey module integrates the crusher, vibrating grizzly feeder, and onboard walkways into a single, preassembled unit for streamlined installation.

Operational Workflow:
1. Feed & Scalping: Runofmine material is deposited onto the integral vibratory grizzly feeder, which scalps out fine undersize material to bypass the crusher, improving overall efficiency.
2. Primary Reduction: Oversize material is directed into the robust jaw crusher chamber, where a steep nip angle and aggressive crushing action reduce material to a predetermined top size.
3. ​Discharge & Conveyance: Crushed product is discharged onto the main plant conveyor belt for transport to secondary crushing or stockpiling.

Application Scope: Ideal for hard rock (granite, basalt), abrasive ores, and recycled concrete in largescale quarrying, mining, and aggregate production.
Limitations: Not suitable for sticky, clayrich materials without prior feeding/scalping modifications. Maximum feed size is constrained by the specific model's grizzly opening and jaw dimensions.

3. CORE FEATURES

Hydraulic Toggle & Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace mechanical toggle plates. | Operational Benefit: Enables safe, remote adjustment of the crusher closed side setting (CSS) for quick product size changes and provides automatic clearing of chamber blockages in minutes versus hours. | ROI Impact: Reduces downtime for routine adjustments by up to 70% and eliminates manual shim handling.
HeavyDuty Fabricated Base Frame | Technical Basis: Unibody construction from hightensile steel with integral motor mounts. | Operational Benefit: Eliminates misalignment issues, reduces structural stress points, and provides a stable platform that minimizes vibration transmission. | ROI Impact: Extends bearing life, reduces foundation requirements, and lowers longterm structural maintenance costs.
Integrated Grizzly Feeder with Bypass Chute | Technical Basis: Stepped grizzly sections with adjustable slope and gap settings. | Operational Benefit: Optimizes crusher efficiency by removing fines prior to crushing, reducing chamber wear and preventing packing. The bypass chute directs fines directly to the product conveyor. | ROI Impact: Increases total system throughput by 815% by relieving the crusher of unnecessary work on smaller material.
Quenched & Tempered Jaw Dies | Technical Basis: Manganese steel dies subjected to controlled heat treatment for optimal hardnesstoughness balance. | Operational Benefit: Provides exceptional resistance to abrasion and fatigue cracking in highimpact crushing conditions. | ROI Impact: Field data shows a typical 2030% increase in liner life over standard manganese dies, directly lowering costperton for wear parts.
Centralized Greasing & PLC Control Interface | Technical Basis: Automated lubrication points routed to a single station with PLC monitoring of crusher parameters. | Operational Benefit: Ensures consistent bearing lubrication, simplifies routine maintenance checks, and allows operators to monitor power draw and alarms from a central location. | ROI Impact: Prevents premature bearing failure—a major cause of unplanned downtime—and reduces daily walkaround time for technicians.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | APC Series Primary Jaw Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Availability (Uptime) | 8590% (scheduled & unscheduled stops) | 9395% (leveraged from field service data) | ~5% increase in productive hours |
| Wear Part Cost/Ton Processed| Baseline (100%)| Approx. 75% of baseline (via extended liner life & optimized kinematics)| ~25% reduction |
| Time for Chamber Clearance| 24 hours (manual)

|<10 minutes (hydraulic toggle reversal)| Up to 95% reduction |
| Throughput Consistency
(with variable feed)| +/ 15% fluctuation

<
>|<+/ 7% fluctuation
(stable power draw & optimized cavity)| Over 50% more consistent output |

5.TECHNICAL SPECIFICATIONS (APC1208 Model Example)

Capacity / Rating: Up to 750 MTPH, dependent on feed material type and closed side setting.
Crusher Aperture: 1200mm x 800mm (48" x 32") feed opening.
Power Requirements: Crusher drive: 160 kW electric motor; Feeder drive: 11 kW electric motor; Hydraulic system: 7.5 kW power pack.
Material Specifications: Main frame: ST52 steel; Jaw dies: Q&T Manganese Steel (14%18%); Cheek plates: AR400 abrasionresistant steel.
Physical Dimensions (LxWxH): Module approx.:12m x 3m x4m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with standard lubrication; optional hightemperature or arctic packages available.

_(Metric Tons Per Hour)_

6\. APPLICATION SCENARIOS

Granite Quarry Expansion

Challenge:
A Southeastern US quarry expanding its primary circuit faced frequent jaw crusher stalls due to occasional oversized slabs exceeding the rated feed size,
leading to costly downtime
and damaged components.

Solution:
Implementation of an APC1208 Primary Jaw Crusher Station equipped with the hydraulic toggle system
and reinforced deck on the grizzly feeder.

Results:
The hydraulic system allowed operators
to clear blockages caused by oversized slabs in under five minutes without entering
the chamber.Productivity logs show a reduction
in blockagerelated downtime from an average of18 hours per month
to less than2 hours,
safeguarding quarterly production targets

Base Course Production for Highway Project

Challenge:
A contractor on a fixedprice highway project needed
to meet strict particle shape specifications
for base course material while processing highly variable riverrun gravel containing abrasive sand content.Wear costs were unpredictable

Solution:
A portable version of
the APC series Primary Jaw Crusher was deployed onsite,
utilizing its CSS adjustment capability
and Q&T jaw dies

Results:
The ability
to make quick CSS adjustments ensured consistent product gradation despite variable feed.The specialized jaw dies demonstrated a22%
increase in life span compared
to previous equipment used on similar material.This predictability allowed accurate forecasting of wear part costs for the project duration

7\. COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around throughput capacity:

Tier1(APC806):UpTo350MTPH–Idealfor midsized quarries or satellite sites

Tier2(APC1208):UpTo750MTPH–Standardfor largescale aggregate production

Tier3(APC1510):UpTo1200MTPH–Forhighvolume mining or major infrastructure projects

Optional Features include:

Dust suppression spray systems,

Heavyduty skid basesfor portable configurations,

Automated wear monitoring sensors,

Extended warranty packages covering major components

Service Packages:

Platinum(5Years):Includes scheduled inspections,
preferential parts dispatch,
and annual mechanical audits

Gold(3Years):Scheduled inspectionsand discounted parts

Silver(1Year):Standard warranty extensionwith inspection

Financing Options:

Flexible leasetoown agreements through partner financial institutions are available,
typically structured over36–60months.Capital expenditure(CAPEX)
versus operational expenditure(OPEX)
models can be discussed based on your company's financial strategy

FAQ Section

Q1:Whatis themaximum recommended compressive strengthof feedmaterialforthe APCseries?

A1:The APCseriesis engineeredfor materials witha compressive strengthupTo350MPa.For harder materials or specific ore types,a technical reviewis recommendedtoselectthe optimal chamber geometryandlinermaterial

Q2:Canthe integratedstationbe retrofittedintoan existingplantlayout?

A2:The modular designallowsfor integrationinto both newand existing circuits.Foundation drawingsandfeed/discharge heightsare providedfor engineering reviewbyyour contractorstoensure compatibilitywithyour currentconveyor systems

Q3:Whatisthe typical leadtimefrom orderto commissioning?

A3.For standard configurationsleadtimesrange from20–24weeksdependingon model tierand current manufacturing scheduleExpedited optionsmay be available subjectto inquiry

Q4.Howdoesthe hydraulic toggle systemimpact routine maintenance?

A4.It significantly simplifiesit.The systemremoves themechanical riskassociatedwith traditional toggle platesLubrication pointsare centralizedReducing daily check timesfor operatorsbyan estimated30%

Q5.Are training resourcesprovidedfor our operationsandmaintenance crews?

A5.Comprehensive trainingis includedwith everysaleThis comprises onsite commissioning trainingbyour field engineersas wellas access todetailed digital manualsandschematicsthrougha dedicated customer portal