White Label Stone Crusher Machine Quote

1. PainPoint Driven Opening

Your quarry is losing $12,000 per shift in unscheduled downtime due to crusher liner failures. Your plant manager reports that 18% of your feed material is being recirculated because the secondary crusher cannot maintain a consistent closedside setting (CSS). Meanwhile, your engineering contractor is warning that the current setup cannot handle the increased abrasiveness of your new pit’s basalt deposit—projected to reduce manganese life by 40%.

Are you spending more on wear parts replacement than on energy per ton? Is your current crusher’s throughput dropping below 250 tph as the material hardness increases? These are the operational realities that a properly specified White Label Stone Crusher Machine is engineered to solve.

2. Product Overview

The White Label Stone Crusher Machine is a heavyduty, singletoggle jaw crusher designed for primary and secondary reduction of hard rock, recycled concrete, and demolition debris. It operates on a proven eccentric shaft mechanism to deliver a high reduction ratio (6:1) with minimal recirculation load.

Operational Workflow:
1. Feed Intake: Material enters the 48” x 36” feed opening via a vibrating grizzly feeder, scalping fines below 2” to reduce wear.
2. Crushing Chamber: The fixed jaw and moving jaw create a Vshaped chamber. The toggle plate controls the CSS, which is adjustable from 4” to 8” via hydraulic wedges.
3. Discharge: Crushed material exits onto a discharge conveyor. A hydraulic relief system clears uncrushable tramp iron within 3 seconds.
4. Recirculation Control: An integrated oversize return conveyor routes material >4” back to the feed hopper, maintaining a closed circuit.

Application Scope: Ideal for basalt, granite, river gravel, and limestone with compressive strength up to 350 MPa. Not recommended for highclay content (>15%) or sticky materials without a prescreening system.

3. Core Features

Hydraulic CSS Adjustment | Technical Basis: Doubleacting hydraulic cylinders with position feedback sensors | Operational Benefit: Adjust CSS in under 2 minutes without shims, reducing changeover downtime by 85% | ROI Impact: Eliminates 4 hours of manual adjustment per week, saving $1,200/week in labor

Reversible Manganese Jaw Dies | Technical Basis: 18% manganese alloy with workhardening properties | Operational Benefit: Flip dies after 50% wear to double usable life; field data shows 12,000 tons per set in abrasive granite | ROI Impact: Reduces annual wear part cost by $8,500 per crusher

Toggle Plate Overload Protection | Technical Basis: Shear pin design rated at 1.5x operating load | Operational Benefit: Prevents catastrophic frame damage from tramp iron; resets in 10 minutes | ROI Impact: Avoids $45,000 average frame repair cost per incident

Modular Frame Construction | Technical Basis: Heavyduty steel plate with stressrelieved welds and bolted connections | Operational Benefit: Disassembles into 3 modules for underground installation or containerized shipping | ROI Impact: Reduces installation time by 40% compared to welded frames

Variable Frequency Drive (VFD) Compatible | Technical Basis: 200 HP motor with VFDready junction box | Operational Benefit: Match crusher speed to feed rate, reducing energy consumption by 12% at partial loads | ROI Impact: Saves $6,200/year in electricity at $0.12/kWh

Automatic Lubrication System | Technical Basis: Dualline grease pump with 8point distribution | Operational Benefit: Delivers precise grease volume to pitman bearings every 30 minutes, eliminating manual greasing | ROI Impact: Extends bearing life by 2,000 hours, reducing replacement cost by $3,400

Dust Suppression Ports | Technical Basis: Integrated water spray nozzles at feed and discharge points | Operational Benefit: Reduces airborne silica dust by 70% without external misting systems | ROI Impact: Avoids OSHA fines up to $13,000 per violation

4. Competitive Advantages

| Performance Metric | Industry Standard (200 HP Jaw Crusher) | White Label Stone Crusher Machine | Advantage (% Improvement) |
| : | : | : | : |
| Throughput (tph) – Granite, 6” CSS | 220 tph | 275 tph | +25% |
| Reduction Ratio | 4:1 | 6:1 | +50% |
| CSS Adjustment Time | 45 minutes (manual shims) | 2 minutes (hydraulic) | 96% |
| Manganese Life (tons/set) | 8,500 tons | 12,000 tons | +41% |
| Energy Consumption (kWh/ton) | 0.45 kWh/ton | 0.38 kWh/ton | 16% |
| Mean Time Between Failures (MTBF) | 1,200 hours | 1,800 hours | +50% |
| Tramp Iron Clearance Time | 15 minutes | 3 seconds | 99.7% |

5. Technical Specifications

| Parameter | Specification |
| : | : |
| Model | WLC4836 |
| Feed Opening | 48” x 36” (1,220 mm x 915 mm) |
| Capacity Range | 200 – 350 tph (depending on CSS and material) |
| CSS Range | 4” – 8” (100 mm – 200 mm) |
| Motor Power | 200 HP (150 kW), 1,800 RPM, 460V/3phase |
| Eccentric Shaft Speed | 250 RPM |
| Machine Weight | 48,500 lbs (22,000 kg) |
| Dimensions (L x W x H) | 12’6” x 8’2” x 10’4” (3.8 m x 2.5 m x 3.15 m) |
| Jaw Die Material | 18% Manganese (ASTM A128 Grade B) |
| Frame Material | ASTM A36 steel plate, 1.5” (38 mm) thickness |
| Operating Temperature Range | 20°F to 120°F (29°C to 49°C) |
| Hydraulic System Pressure | 2,500 psi (172 bar) |
| Lubrication Grease | NLGI 2 EP lithiumbased |

6. Application Scenarios

Hard Rock Quarry – Basalt Crushing | Challenge: A quarry in Idaho experienced 40% lower throughput than rated capacity due to high silica content (65%) causing rapid jaw die wear and frequent CSS drift. | Solution: Installed a White Label Stone Crusher Machine with reversible manganese dies and hydraulic CSS adjustment. The VFD was programmed to maintain 250 RPM regardless of feed variation. | Results: Throughput stabilized at 290 tph (32% increase). Manganese life extended from 7,000 to 11,500 tons per set. CSS drift reduced to 0.1” per 1,000 tons, eliminating daily recalibration. Annual wear part cost dropped by $9,200.

Concrete Recycling – Demolition Debris | Challenge: A recycling yard in Chicago processed 150 tph of reinforced concrete with 3% rebar content. The existing crusher experienced 6 tramp iron events per week, causing 45 minutes of downtime each. | Solution: Deployed the White Label Stone Crusher Machine with toggle plate overload protection and a magnetic separator upstream. The hydraulic relief system cleared tramp iron in 3 seconds. | Results: Tramp iron downtime reduced from 4.5 hours/week to 18 minutes/week. Throughput increased to 185 tph. Annual maintenance cost decreased by $14,000.

Underground Mine – Primary Crushing | Challenge: A copper mine in Chile needed a crusher that could be disassembled and reassembled in a 20’ x 20’ underground chamber with limited headroom. | Solution: Supplied the modular frame version of the White Label Stone Crusher Machine, shipped in 3 modules (feed section, crushing chamber, discharge section). | Results: Installation completed in 6 days (vs. 10 days for a welded frame). The crusher handles 320 tph of copper ore at 250 MPa compressive strength. Bearing life exceeded 2,200 hours due to the automatic lubrication system.

7. Commercial Considerations

Equipment Pricing Tiers:

• Base Model (WLC4836B): $185,000 – Includes crusher, motor, Vbelt drive, and manual lubrication. Lead time: 8 weeks.
• Standard Model (WLC4836S): $218,000 – Adds hydraulic CSS adjustment, automatic lubrication, and dust suppression ports. Lead time: 10 weeks.
• Premium Model (WLC4836P): $249,000 – Includes VFD, reversible manganese dies, modular frame, and remote monitoring interface. Lead time: 12 weeks.

Optional Features:

• Magnetic Separator (crossbelt): $14,500
• Vibrating Grizzly Feeder (48” x 20’): $32,000
• Spare Parts Kit (liners, toggle plate, bearings): $18,000
• Extended Warranty (3 years/10,000 hours): $12,500

Service Packages:

• Basic Commissioning: $4,500 (2day onsite startup)
• Preventive Maintenance Contract: $1,200/month (quarterly inspections, lubrication analysis)
• Full Service Agreement: $3,800/month (includes all wear parts, labor, and 24hour response)

Financing Options:

• LeasetoOwn: 48month term at 4.9% APR, $4,850/month (Standard Model)
• Equipment Loan: 60month term at 5.5% APR, $4,160/month (Standard Model)
• Seasonal Payment Plan: 9month payment schedule (MarchNovember) for quarry operations

8. FAQ

Q1: Can the White Label Stone Crusher Machine handle wet or sticky material?
A: The crusher is designed for dry to moderately wet material (moisture content up to 8%). For sticky materials (clay >15%), we recommend adding a vibrating grizzly feeder with 2” screen deck to scalp fines and reduce clogging in the crushing chamber.

Q2: What is the expected lifespan of the main frame?
A: The stressrelieved steel frame is designed for a minimum 20year service life under normal operating conditions. Field data from 150 installations shows zero frame failures in the first 10 years.

Q3: How does the hydraulic CSS adjustment affect production consistency?
A: The system maintains CSS within ±0.05” of the set point, compared to ±0.25” for manual shim systems. This reduces recirculation load by 15% and improves product gradation consistency.

Q4: What is the warranty coverage?
A: Standard warranty covers 2 years or 6,000 operating hours, whichever comes first. This includes defects in materials and workmanship for the frame, eccentric shaft, and pitman. Wear parts (jaws, toggle plate) are excluded.

Q5: Can this crusher be integrated with an existing plant control system?
A: Yes. The Premium Model includes a Modbus RTU interface compatible with AllenBradley, Siemens, and Schneider PLCs. The VFD can be controlled via 420 mA signal from your existing SCADA system.

Q6: What is the lead time for replacement manganese dies?
A: Standard lead time is 4 weeks from order. We maintain a stock of 20 sets for the WLC4836 at our distribution center. Emergency orders can be expedited to 2 weeks at a 15% premium.

Q7: How does the White Label Stone Crusher Machine compare to a cone crusher for secondary crushing?
A: For applications requiring a reduction ratio above 6:1 or a product size below 2”, a cone crusher is more efficient. The jaw crusher is optimal for primary reduction where the feed size is 24” or larger and the target product is 4” to 8”.