1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? Key challenges in primary crushing operations often include:
High Wear Part Costs: Frequent replacement of manganese jaws or concaves due to abrasive feed material, costing tens of thousands annually in parts and labor.
Unscheduled Downtime: Catastrophic failure from uncrushable material or component fatigue, halting your entire processing line for 824 hours or more.
Inconsistent Product Gradation: Fluctuating output sizes create bottlenecks for secondary crushers and screening circuits, reducing overall plant throughput by 1530%.
Excessive Energy Consumption: Older, inefficient drive systems and poor chamber designs lead to power costs that are disproportionate to actual tonnage crushed.
Rigidity to Feed Variation: Inability to handle a mix of hard abrasive rock and occasional clay or moisture without choking or packing.

Is your primary crushing station a source of constant maintenance concern and cost overruns? The solution lies in selecting a primary jaw crusher engineered not just for capacity, but for total cost of ownership.

2. PRODUCT OVERVIEW

The cornerstone of any hard rock processing plant is a robust primary jaw crusher. This machine is designed as the first stage of size reduction, accepting large runofmine (ROM) feed directly from the quarry face. Its operational workflow is straightforward yet critical:
1. Feed Intake: ROM material (up to 80% of crusher gape) is loaded into the vibrating grizzly feeder (VGF) section, which scalps out fines.
2. Compressive Crushing: Material enters the fixed and moving jaw dies. The elliptical motion applies immense compressive force, breaking rock against rock.
3. Discharge: Crushed material exits through the adjustable discharge opening (CSS), with size determined by the gap at the bottom of the chamber.

Application Scope: Ideal for hightonnage processing of granite, basalt, trap rock, and other abrasive aggregates. It is the default choice for stationary primary crushing stations.
Key Limitations: Not suitable for highly recycled concrete with excessive rebar without prescreening. Performance on very soft, nonabrasive stone may not justify capital expenditure compared to simpler impactors.

3. CORE FEATURES

Deep Crushing Chamber & Aggressive Nip Angle | Technical Basis: Optimized kinematics for increased feed acceptance and reduced bridging | Operational Benefit: Your operators experience fewer blockages and achieve higher volume reduction in a single pass | ROI Impact: Up to 10% higher throughput from improved feed kinetics, maximizing capex utilization

HeavyDuty Fabricated Frame with StressRelieved Design | Technical Basis: Finite Element Analysis (FEA) ensures uniform stress distribution under peak loads | Operational Benefit: The structure withstands tramp metal events and cyclical loading without developing fatigue cracks | ROI Impact: Extended structural life beyond 20+ years under severe duty, protecting longterm asset value

Hydraulic Toggle Adjustment & Clearing System | Technical Basis: Replaceable hydraulic cylinder for setting adjustment and overload protection | Operational Benefit: CSS changes can be made in minutes versus hours, and uncrushables are automatically cleared without manual intervention | ROI Impact: Reduces downtime for adjustments by over 90% and prevents costly damage from stall events

QuarryGrade Spherical Roller Bearings & Labyrinth Seals | Technical Basis: Oversized bearings rated for heavy radial and thrust loads with multistage protection from dust ingress | Operational Benefit: Bearing service life exceeds 25,000 hours under normal conditions with reliable temperature performance | ROI Impact: Eliminates premature bearing failures that typically cost $15k$40k per event in parts and lost production

BoltOn Manganese Jaw Dies with Multiple Tooth Profiles | Technical Basis: Reversible/wearable dies secured by mechanically locked wedges for safety and ease of service | Operational Benefit: Your maintenance crew can perform liner changes safely within a single shift using standard tools | ROI Impact: Reduces liner changeout time by up to 50%, increasing plant availability

PLCAutomated Lubrication & Condition Monitoring Ports | Technical Basis: Centralized greasing points for toggle area with ports for vibration/temperature sensors | Operational Benefit: Enables predictive maintenance scheduling based on actual wear data rather than calendar intervals | ROI Impact: Prevents 80% of lubricationrelated failures and allows justintime parts ordering

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Our Primary Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tons per Hour per kW (Abrasive Granite) | 4.5 5.2 tph/kW | 5.8 6.4 tph/kW | +15% Energy Efficiency |
| Jaw Die Life (Basalt Application) | 120,000 150,000 MTONs | 180,000 220,000 MTONs| +40% Wear Life |
| Mean Time Between Failure (MTBF)| ~1,500 hours| >2,200 hours| +46% Operational Uptime |
| CSS Adjustment Time (Mechanical vs Hydraulic)| 46 hours| <30 minutes| 90% Downtime |
| Noise Emission at 1 Meter| ~110 dBA| <105 dBA| Compliant with stricter site regulations |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 300 1,800 Mtph (varies by feed material & CSS)
Feed Opening: From \(47" \times36"\) up to \(60" \times48"\) (1,200mm x 900mm up to 1 ,500mm x 1 ,200mm)
Max Feed Size: Up to \(48"\) (\(1 ,200mm\)) edge length
Power Requirement: \(150 \(350 kW\) electric motor (\(200\)\(500 HP\)), Vbelt driven
Crusher Weight (Frame & Flywheels): \(55 ,000 \(130 ,000 lbs\) (\(25\)\(59 metric tons\)
Material Specifications: Main frame – fabricated \(AR400\) steel; Jaw dies – \(14\)\(18\%\) manganese steel; Shaft – forged alloy steel.
Physical Dimensions (LxWxH): Approximately \((Length = \(1 .5x Feed Opening\)) x \((Width = \(2 .5x Feed Opening\)) x \((Height = ~\(10 ft\))\)
Environmental Operating Range: Designed for ambient temperatures from \(20^\circ C\) to \(+45^\circ C\). Dust seals effective in conditions up to \(10g/m^3\) particulate concentration.

6. APPLICATION SCENARIOS

Large Granite Quarry Expansion

Challenge A major aggregate producer needed to increase primary circuit throughput by 25 % without expanding their truck dump pocket or primary crusher footprint due to space constraints.
Solution Implementation of our highcapacity primary jaw crusher featuring the deepchamber design and an optimized eccentric throw speed profile.
Results Achieved a 28 % increase in tons per hour within the same foundation envelope while reducing specific energy consumption by 11 %. Payback period was calculated at 22 months based on increased sales volume alone.

Urban Recycling & Hard Rock Operation

Challenge A contractor processing both demolished concrete and natural limestone faced constant jamming from rebar in concrete slabs and needed rapid product size changes between different contracts.
Solution Deployment of our model equipped with a hydraulic toggle system with automatic release/reset functionality.
Results Uncrushable rebar bundles are now cleared in under 2 minutes automatically . Changeover between product settings (\(4 " base vs . 2 " drainage layer\)) is completed in under an hour versus a full shift previously , increasing plant flexibility .

7. COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on size/capacity:
Tier I (\(\(1200 tph\)): Customengineered solutions with performance guarantees ,extended wear packages ,and dedicated engineering support .

Optional Features:
Integrated motor base & drives .
Steel structure / walkway package .
Belt scales & tramp metal detection systems .
Remote monitoring telematics package .

Service Packages:
1 . Basic Warranty : 12 months / 2 ,000 hours on parts .
2 . Extended Performance Plan : 36 months / 10 ,000 hours covering major components with scheduled inspections .
3 . FullService Contract : Includes planned liner changes ,predictive maintenance analysis ,and guaranteed uptime percentages .

Financing Options available through partners include capital leases ,operating leases,and projectbased financing tailored to greenfield developments or expansion projects .

8.FAQ

Q What if my feed material varies significantly in hardness ?
A Our jaw crushers are designed with an optimal nip angleand crushing stroke tomaintain efficient performance acrossa rangeof materials .Field data shows consistent product gradation even when switching between moderately abrasive limestoneand very hard trap rock .

Q How does this machine integratewith my existing secondary circuit ?
A We provide detailed interface drawingsfor chute workand structural support .Our technical team can reviewyour entire flow sheetto ensuretheprimary dischargegradation optimizesyour secondarycrusher'sloadand minimizescirculating loads .

Q Whatisthe typical installationand commissioning timeline ?
A Fora complete stationaryprimary crushing stationincluding feeder,crusher,and discharge conveyor,the timelineis typically1216weeksfromorder toreleaseforproduction.This includesfoundationdesignreview,majorcomponentassembly,and supervisedstartupwith operator training .

Q Arewear parts readily available ?
A Yes.We maintaina globalnetworkof warehousesto ensurecritical wearpartslikejawdiesareavailablefor express shipment.Inventory levelsare monitoredagainstyour consumptionrates topreventstockouts .

Q Can you provideperformance guarantees ?
A ForTier IIand III solutions,yes.We offerguaranteeson minimumthroughput(tph),maximumpower consumption(kW/t),and maximumwearpartconsumption(grams/ton)basedon your specificfeedmaterialanalysis .

Q What trainingis providedfor our operationsand maintenance crews ?
A We providecomprehensiveonsite trainingduringcommissioningcovering safeoperation,routine maintenance procedures,and advancedtroubleshooting.A detailedoperationsmanualwithparts listsis also suppliedin digitalformat .

Q Do you offertradeinoptionsfor ourexistingagingprimarycrusher ?
A Yes.We havean equipmentrefresh programthatcan provideavaluationforyour legacy machineryto beappliedtowardsthe purchaseof anewprimaryjawcrushersolution .