1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core crushing circuit is often the source of critical bottlenecks. Common challenges include:
Excessive Wear Part Consumption: Premature failure of jaw plates, mantles, and concaves leads to frequent, costly shutdowns and soaring consumables budgets.
Inconsistent Product Gradation: Fluctuations in feed material cause offspec product, resulting in pile contamination, recrushing, and rejected loads.
High Energy Intensity: Older crushing technology consumes disproportionate power per ton of output, directly impacting your bottom line.
Unscheduled Maintenance Downtime: Reactive repairs to critical components create production chaos and delay project timelines.
Limited Configuration Flexibility: Fixed crushers struggle to adapt to changing feed stock or final product requirements, forcing suboptimal operation.

Is your primary crushing station a cost center or a reliable profit driver? The solution lies in specifying machinery engineered to directly address these financial and operational pressures.

2. PRODUCT OVERVIEW

The modern jaw crusher represents the cornerstone of hard rock reduction in quarrying, mining, and demolition recycling operations. Engineered as a robust compressive crusher, its function is the firststage reduction of large runofmine material to a manageable size for downstream processing.

Operational Workflow:
1. Feed Intake: Large raw material (up to 80% of crusher gape) is loaded into the vibrating grizzly feeder (VGF) section, which scalps out fines to bypass the chamber.
2. Compressive Crushing: Material enters the fixed and movable jaw die cavity. The elliptical motion of the movable jaw applies immense compressive force, breaking rock against the stationary jaw.
3. Discharge Setting Adjustment: The crushed product exits at the bottom opening. The Closed Side Setting (CSS) is hydraulically adjustable to precisely control top product size without manual shim changes.

Application Scope & Limitations:
Scope: Ideal for primary crushing of abrasive materials like granite, basalt, and recycled concrete. Suited for stationary plants or mobile tracked setups.
Limitations: Not optimal for soft, nonabrasive stone (use impact crushers). Requires prescreening via a grizzly for optimal efficiency. Maximum reduction ratios are typically 6:1 to 8:1.

3. CORE FEATURES

HEAVYDUTY WELDED FRAME | Technical Basis: Finite Element Analysis (FEA)optimized highgrade steel fabrication | Operational Benefit: Eliminates stress cracking under maximum load cycles; provides stable platform for precision bearing alignment | ROI Impact: Extends structural life beyond 20+ years, eliminating risk of catastrophic frame failure and associated replacement costs.

HYDRAULIC CSS ADJUSTMENT | Technical Basis: Integrated hydraulic cylinders replace traditional manual shim systems | Operational Benefit: Enables remote adjustment of discharge setting in minutes for product changeover or wear compensation | ROI Impact: Reduces downtime for setting changes from hours to minutes, increasing plant utilization by up to 5% annually.

DEEP SYMMETRICAL CRUSHING CHAMBER | Technical Basis: Optimized nip angle and longer feed opening design | Operational Benefit: Promotes rockonrock particletoparticle crushing, reduces slabby product, and ensures even wear across jaw dies | ROI Impact: Improves wear part life by 1530% and produces more cubical product for better downstream throughput.

DUALACTING TOGGLE RELEASE SYSTEM | Technical Basis: Automated hydraulic cylinder with accumulator protection | Operational Benefit: Automatically releases tramp metal or uncrushable material by retracting the movable jaw, then resets to original CSS | ROI Impact: Prevents costly damage to pitman and bearings; avoids hours of manual clearing downtime per event.

CENTRALIZED AUTOMATED GREASING SYSTEM | Technical Basis: Programmable pump delivering precise grease volume to all key bearings | Operational Benefit: Ensures optimal bearing lubrication regardless of operator schedule; extends bearing service life | ROI Impact: Reduces bearingrelated failures by over 70% and lowers manual maintenance labor requirements.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Part Life (Mn/Ton) | Based on standard manganese steel | Proprietary alloy & chamber design yields higher workhardening capability| +2025% |
| Energy Consumption (kWh/Ton) | Varies with model & material | Direct drive & optimized kinematics reduce mechanical losses| 1015% |
| CSS Adjustment Time (Minutes)| Manual shims (~60120 min) | Hydraulic system with pushbutton control (94% through rapid adjust & automated protection systems| +59% absolute increase |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 150 1,600 MTPH (highly material dependent)
Feed Opening Range: 800mm x 500mm up to 1,600mm x 2,000mm
Power Requirements: 75 kW 400 kW electric motor; Tier IV Final / Stage V diesel options available for mobile units.
Material Specifications: Highstrength welded steel frame (ASTM A572); Jaw dies available in standard manganese (14%18%), premium manganese (21%23%), or composite alloys for specific abrasion/corrosion applications.
Physical Dimensions (Example Model): Approx. Length: 4.5m; Width: 3.2m; Height: 3.8m; Weight: ~48,000 kg.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +45°C; dustsealed bearings and components standard for highdust environments.

6. APPLICATION SCENARIOS

Granite Quarry Primary Station | Challenge: A Southeast US quarry faced excessive downtime from weekly manual CSS adjustments and premature jaw die wear causing inconsistent yield on 57 stone. Unplanned tramp metal events halted production for half a day on average.| Solution: Implementation of a heavyduty jaw crusher with hydraulic CSS adjustment and dualacting toggle release system.| Results: CSS changeovers reduced from 90 minutes to under 5 minutes. Wear part life extended by 22%. Two tramp metal events were cleared automatically within one shift without stoppage. Annual throughput increased by an estimated 12%.

Urban Concrete Recycling Plant | Challenge Processing variable demolition concrete with high rebar content led to frequent jamming in the primary crusher and dangerous manual clearing procedures.| Solution Deployment of a mobile tracked jaw crusher equipped with an aggressive bypass chute for fines removal and a robust automatic unblocking system.| Results Uncrushable contaminants are ejected reliably within seconds Plant availability improved by over three operational days per month Safety incidents related to manual clearing were eliminated

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on capacity size range entrylevel standardduty models midrange heavyduty models premium ultraheavyduty configurations with full automation packages

Optional Features Include
Integrated motor base frame
Automatic wear part monitoring sensors
Dust suppression spray systems
Rock breaker boom system interface

Service Packages Offered
Basic Warranty includes parts labor for first year
Extended Performance Plans covering upto five years including scheduled inspections
Onsite Operator Training Programs

Financing Options Available through partnered vendors include capital lease operating lease longterm rental with purchase option tailoredto balance sheet requirements

8 FAQ

Q What is requiredto integrate this into my existing plant flow
A Our jaw crushers are designedwith standardized discharge heightsand feed hopper interfaces Electrical controls can be prewiredto accept your plant PLC signals Sitespecific foundation drawingsare provided

Q How does the automated greasing systemimpact my maintenance schedule
A It replaces daily manual greasing checks The systemis programmedbased on operating hoursand can be monitored remotely It typically requiresa bulk grease refillevery weeks dependingon usage

Q Can I use my existingwear partsfrom another manufacturer
A No For guaranteed performanceand safetywear partsare engineeredas a systemwiththe crusherchamber geometry UsingnonOEM parts can void warrantiesand reduceefficiency

Q What isthe typical lead timefor deliveryand commissioning
A For standardmodelslead timeis weeks after order confirmation Commissioningby our field service engineersis recommendedand scheduledat timeof purchase

Q Are financingoptions availablefor used equipmentor rentaltoown
A Yes we offerflexible commercialtermson both newand certifiedpreowned units Shorttermrental contractsare also availablefor projectbasedwork