H1: Optimize Your Quarry Output with Advanced Limestone Crushing Solutions

1. PAINPOINT DRIVEN OPENING

Managing a limestone quarry’s primary crushing station is a critical bottleneck. Inconsistent feed, abrasive material, and relentless operational demands translate directly into profit erosion. Are you facing these persistent challenges?
Unscheduled Downtime: Unplanned stoppages due to crusher blockages, wearrelated failures, or component breakdowns halt your entire downstream process. Industry averages indicate that each hour of primary crushing downtime can cost over $5,000 in lost production and labor.
High Operational Costs: Premature wear on manganese steel jaws and liners requires frequent, costly replacements. Inefficient power draw from poorly matched or outdated crushers inflates your energy expenditure, one of the plant's highest variable costs.
Inconsistent Product Sizing: Variability in feed size and moisture content leads to uneven discharge from the primary crusher. This places undue stress on secondary and tertiary stages, reducing their efficiency and compromising final product gradation.
Rigid Setup Limitations: Fixed primary crusher installations lack the flexibility to adapt to changing face locations or varying geology, leading to extended rehandling with loaders and increased fuel costs.

The central question for plant managers is clear: how can you achieve higher throughput with greater reliability while controlling the costperton metric?

2. PRODUCT OVERVIEW

The Mobile Primary Jaw Crusher represents a paradigm shift in initial limestone size reduction. This selfcontained trackmounted unit integrates a highcapacity jaw crusher, vibrating grizzly feeder, and onboard power system into a single mobile platform.

Operational Workflow:
1. Direct Face Feeding: The unit positions directly at the quarry face or shot pile, minimizing haulage distance for excavators or wheel loaders.
2. Integrated PreScreening: The aggressive grizzly feeder bypasses fines directly to the discharge conveyor, reducing crusher cavity wear and increasing effective capacity.
3. Primary Crushing: A robust jaw crusher reduces runofquarry limestone to a consistent nominal size suitable for conveyor transport to secondary processing.
4. Direct Discharge: Crushed material is conveyed to either a stockpile or directly into the feed hopper of your downstream plant.

Application Scope & Limitations:
Scope: Ideal for largescale quarrying operations, mining contracts requiring relocation, and operations with multiple faces or satellite deposits. Optimal for limestone with a compressive strength below 250 MPa.
Limitations: Not designed for highly abrasive silicified limestone without specific liner options. Maximum feed size is governed by crusher model dimensions; oversize boulders require prebreaking.

3. CORE FEATURES

Direct Feed Optimization | Technical Basis: Integrated vibrating grizzly feeder (VGF) with bypass chute | Operational Benefit: Removes fines prior to crushing, reducing chamber wear and preventing packing | ROI Impact: Field data shows up to 15% reduction in liner wear costs and a 1020% increase in effective throughput.

Hydraulic Adjustment & Clearing | Technical Basis: PLCcontrolled hydraulic system for CSS adjustment and uncrushable release | Operational Benefit: Enables quick product size changes and automatic clearing of stall events without manual intervention | ROI Impact: Reduces adjustment time by 90% versus manual shims; prevents major downtime from tramp metal events.

DieselElectric Hybrid Drive | Technical Basis: Tier 4 Final diesel engine generating power for allelectric crusher & conveyor drives | Operational Benefit: Eliminates clutch/belt maintenance; provides optimal torque at variable speeds; significantly quieter operation | ROI Impact: Industry testing demonstrates up to 25% lower fuel consumption compared to direct dieselhydraulic drives.

Advanced Wear Part Design | Technical Basis: Computermodeled jaw die profiles using ultrahigh tensile manganese steel | Operational Benefit: Achieves more interparticle crushing for better shape, extends service life through optimized kinematics | ROI Impact: Increases wear life by an average of 30%, lowering costperton for consumables.

Intelligent Process Control (IPC) System | Technical Basis: CANbus system monitoring load, power draw, temperature, and feed level | Operational Benefit: Automatically regulates feeder speed to maintain optimal cavity fill and protects against overloads | ROI Impact: Maximizes throughput while preventing damage; operator telemetry reduces troubleshooting time.

Rapid Relocation Capability | Technical Basis: Trackmounted chassis with hydraulic setup functions (folding conveyors/hydraulic legs) | Operational Benefit: Full relocation between faces can be completed in under 30 minutes by a single operator | ROI Impact: Eliminates need for multiple fixed plants; enables singleunit coverage of large or complex sites.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Fixed Plant) | Mobile Primary Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Setup/Relocation Time| Days (civil works required) | 95% Faster |
| Fuel Consumption per ton| Baseline (Loader haulage + fixed plant) | Direct face feeding + hybrid drive| Up to 25% Reduction |
| Liner Wear Life (Mn14%)| Standard profile design| Optimized computermodeled profile| ~30% Extension |
| Operational Flexibility| Fixed location; limited feed points| Follows the face; multiple deposit sites| Transformational |
| Labor for CSS Adjustment| Manual shim adjustment (~2 hours)| Hydraulic adjustment via HMI (~5 mins)| ~90% Reduction |

5. TECHNICAL SPECIFICATIONS

Model Reference: MPJC130
Crusher Type: Single Toggle Jaw Crusher
Feed Opening: 1,300 x 900 mm
Maximum Feed Size: 800 mm edge length
Closed Side Setting (CSS) Range: 100 250 mm (hydraulically adjustable)
Capacity Range (Limestone): Up to 600 tonnes per hour (dependent on CSS & material)
Drive System: DieselElectric Hybrid – Tier 4 Final diesel engine generating power for electric crusher motor & conveyors.
Main Conveyor: Belt width: 1,400 mm / Discharge height: ~4.2 m (hydraulically adjustable)
Feeder: Vibrating Grizzly Feeder (VGF) with integral prescreen section.
Track Mobility: Hydraulic drive system for onsite movement.
Frame & Components: Highgrade structural steel; abrasionresistant steel liners in hopper and chutes.
Operating Temperature Range: 20°C to +45°C
Dust Suppression: Integrated spray bar system manifold ready for connection.

6. APPLICATION SCENARIOS

Large MultiFace Quarry Operation | Challenge A major cement producer needed to reduce haulage costs from three distinct faces over a 2km site area while maintaining consistent feed to their central processing plant.| Solution Deployment of one Mobile Primary Jaw Crusher relocated every 46 weeks between faces based on extraction sequencing.| Results Elimination of two dedicated haul trucks resulted in annual fuel savings exceeding $180k. Consistent primary product improved secondary cone crusher efficiency by an estimated 8%.

New Greenfield Site Development Challenge A contractor won a shortterm mining lease but faced prohibitive capital costs for installing fixed crushing infrastructure.| Solution Utilizing a Mobile Primary Jaw Crusher on a rentalwithpurchaseoption plan provided immediate crushing capability without permanent investment.| Results The site achieved full production within two weeks of equipment arrival. The client processed over 500kt of limestone during the contract period with positive net cash flow from month one.

7. COMMERCIAL CONSIDERATIONS

Our solutions are offered through flexible commercial models tailored to your operational timeline:

Equipment Pricing Tiers
Base Configuration MPJC130 Unit
Advanced Package Includes IPC System upgraded dust suppression fan package
Arctic/Package Includes coldweather engine preheaters insulated hydraulics

Optional features include magnetic separators radio remote control extended discharge conveyors

Service Packages:
Platinum Support Plan Includes scheduled maintenance parts kits labor priority response guaranteed uptime commitment
Gold Maintenance Plan Covers all scheduled servicing inspections with parts at preagreed rates

Financing Options Available:
Full capital purchase operating lease rental agreements renttoown structures tailored financing can be arranged through our industrial partners

8.FAQ

What is the typical lead time from order commissioning?
For standard models lead time is typically weeks Custom configurations may require additional time Detailed project planning is initiated upon order

How does this unit integrate with my existing secondary plant?
The unit discharges via an onboard conveyor designed stockpile material or integrate directly into your existing plant feed hopper Conveyor length discharge height are specified during initial consultation

What are the ongoing maintenance requirements?
Daily greasing walkaround checks Weekly inspection of wear parts The IPC system provides predictive maintenance alerts Service intervals are at recommended hour milestones outlined in the support plan

Can it handle other materials besides limestone?
While optimized for limestone applications are possible for other aggregates like granite basalt demolition concrete subject specific model configuration liner selection review

What training is provided operators maintenance staff?
We provide comprehensive onsite operational training technical manuals access our online portal video library Training focuses safe efficient operation basic troubleshooting procedures