1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent vos marges bénéficiaires globales ou minières? Les principaux défis des opérations de concassage primaire comprennent souvent:

Temps d'arrêt excessif pour la maintenance: Les changements fréquents de revêtement et les ajustements mécaniques interrompent toute votre chaîne de traitement, coûtant des milliers de dollars par heure en perte de production.
Arrêts imprévus chez Tramp Metal: Unseen contaminants cause significant damage to crusher internals, leading to catastrophic failure and costly repairs.
Gradation du produit incohérente: Fluctuations in feed material or wear patterns result in offspec product, forcing recrushing and reducing plant throughput efficiency.
Coûts opérationnels élevés: Rising energy consumption per ton and the frequent replacement of highwear components directly impact your bottom line.
Rigidité pour alimenter les variations: Fixed geometry crushers struggle with changing feed sizes or material hardness, provoquant des goulots d'étranglement.

Is your primary crusher a reliable asset or a constant source of concern? The solution requires engineering focused on durability, accessibilité, and process stability.

2. APERÇU DU PRODUIT

The Bespoke JC5000 is a highcapacity, Concasseur à mâchoires à bascule unique conçu pour les applications de concassage primaire les plus exigeantes dans le secteur minier, carrière, and heavyduty recycling. Its robust design prioritizes continuous operation with minimal intervention.

Flux de travail opérationnel:
1. Consommation alimentaire: Gros matériaux provenant de mines ou de carrières (jusqu'à 1300mm) est dirigé vers les profondeurs, chambre de concassage sans étouffement.
2. Concassage compressif: The aggressive elliptical motion of the singletoggle jaw applies intense compressive force against the fixed jaw, effectively breaking even the hardest abrasive rock.
3. Décharge & Autorisation: Le matériau broyé sort par l'ouverture de déchargement, with a hydraulic toggle tensioning and release system providing automatic protection against uncrushables.

Champ d'application: Idéal pour l'exploitation minière de roches dures (minerai de fer, gold bearing ore), carrières de granit/basalte, et traitement des scories. Designed as a stationary primary unit for plants targeting sustained throughputs between 750 1500 mtph depending on material and closed side setting.

Limites: Non conçu pour le dimensionnement de produits ultrafins (secondary/tertiary roles) or processing of wet, matériaux collants sans scalpage préalable. Requires a solid foundation and appropriate feed system integration.

3. CARACTÉRISTIQUES PRINCIPALES

Cadre robuste & Soulagement du stress soudé | Base technique: Analyse par éléments finis (FEA) optimized steel fabrication with postweld heat treatment | Avantage opérationnel: Eliminates frame fatigue cracking under cyclical loads; ensures longterm structural integrity in 24/7 opérations | Impact sur le retour sur investissement: Extends service life by decades; prevents catastrophic frame failure requiring total unit replacement.

Bascule hydraulique & Système de réglage | Base technique: Integrated hydraulic ram for toggle tensioning and automatic clearing | Avantage opérationnel: Allows quick adjustment of CSS under load and automatically releases tramp metal, resetting itself without manual intervention | Impact sur le retour sur investissement: Reduces unplanned downtime from tramp events by up to 80%; enables precise product control without stopping.

Quarry+ Jaw Die Design | Base technique: Optimized tooth profile and thicker manganese sections based on cavity dynamics simulation | Avantage opérationnel: Increases wear life by promoting interparticle crushing; reduces frequency of die rotation/replacement cycles | Impact sur le retour sur investissement: Réduit le coût des pièces d'usure; extends campaign life between maintenance stops by an average of 35%.

Entraînement direct via courroies trapézoïdales & TEFC Motor | Base technique: Hightorque motor connected via multiple Vbelts to flywheel shaft | Avantage opérationnel: Provides smooth power transmission, absorbs load shocks better than directcoupled drives; standard TEFC motor suits harsh environments | Impact sur le retour sur investissement: Reduces stress on drive components; lowers maintenance complexity; improves overall electrical efficiency.

Integrated PreFabricated Installation System | Base technique: Unit supplied with preengineered base frame, faux-châssis du moteur, and alignment aids | Avantage opérationnel: Dramatically reduces field installation time and ensures perfect alignment for optimal vibrationfree operation | Impact sur le retour sur investissement: Réduit le temps de mise en service jusqu'à 50%, accélérer les délais de production.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Concasseurs à mâchoires comparables) | Bespoke JC5000 Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Porter la vie (Matrices de mâchoire)| Based on standard manganese profiles | Quarry+ design with thickened sections & cinématique optimisée| +3040% durée de vie prolongée |
| Temps de récupération du métal clochard| Manual clearing requiring disassembly (~48 heures) | Hydraulic toggle autoreset cycle (<10 minutes) |95% temps d'arrêt |
| Disponibilité annuelle| 8590% (changements de revêtement d'affacturage & ajustements)| Prise en charge des données de terrain >94% disponibilité| +45% augmentation absolue |
| Énergie par tonne concassée| Varies significantly with setting & matériel| Cinématique optimisée & chamber design reduce wasteful motion| 510% amélioration |
| Installation/Commissioning Period| 57 days with foundation work & alignement| Prefabricated system reduces mechanical assembly time |40% installation labor |

_Availability based on comparable duty in hard rock applications._

5. SPÉCIFICATIONS TECHNIQUES

Ouverture d'alimentation: 1300mm x 1600mm (51" x 63")
Taille maximale d'alimentation: Up to 1100mm (43")
Plage de réglage côté fermé: 150mm 300mm (6" 12")
Plage de capacité: 750 1500 tonnes métriques par heure (varies with material density, gradation des aliments, et CSS)
Exigence de puissance d'entraînement: 200 kW / 250 Moteur électrique HP (TEFC)
Poids total (Concasseur uniquement): Environ 86,000 kilos
Spécifications des matériaux clés:
Cadre: Plaque d'acier fabriquée (SAE 1020), soulagé du stress.
Swing Jaw/Fixed Jaw: Highstrength cast steel.
Matrices de mâchoire: Acier au manganèse de première qualité (14%18%).
Arbre excentrique: Acier allié forgé EN24/34CrNiMo6+.
Plage de température de fonctionnement: 20°C à +45°C (4°F à +113°F)
Foundational Requirements: Dessins civils détaillés fournis; requires substantial mass concrete foundation.

6. SCÉNARIOS D'APPLICATION

Hard Rock Gold Mine – Primary Ore Reduction

Défi: A West African gold mine faced excessive downtime from weekly jaw die rotations and monthly maintenance stops on their aging primary crusher. Unpredictable wear was causing throughput fluctuations.
Solution: Installation of a Bespoke JC5000 jaw crusher with Quarry+ dies and hydraulic toggle system.
Résultats: Achieved a consistent campaign life of 6 weeks between die rotations. The hydraulic system cleared two major tramp metal events without stoppage. Annual availability increased from 86% à 93%, contributing to an estimated 18,000 additional tons processed annually.

Granite Quarry – Aggregate Base Production

Défi: A large quarry supplying road base material needed more consistent product gradation to meet strict DOT specifications without secondary recrush. Their existing crusher produced excessive flaky material.
Solution: Implementation of the JC5000 with its optimized crushing chamber geometry and easyadjust hydraulic CSS control.
Résultats:
CSS adjustments under load allowed operators to finetune output in minutes versus hours. The improved nip angle produced a more cubical product at the primary stage,
reducing load on secondary cone crushers by 15%. Overall plant yield of inspec material increased by 8%.

7. CONSIDÉRATIONS COMMERCIALES

The Bespoke JC5000 is offered as a capital investment designed for longterm operational payback.

Niveau de prix de l’équipement de base: Includes crusher assembly,
système de réglage hydraulique à bascule,
matrices à mâchoires standard,
drive sheaves,
and documentation pack.

Fonctionnalités facultatives & Mises à niveau
– Automated Greasing System
– Wear Monitoring Kit (laser profile)
– Special Alloy Jaw Dies for highly abrasive feeds
– Custom SkidMounting for semimobile applications

Forfaits de services:
1. Pack d'assistance à la mise en service
2.Contrat de maintenance planifiée
3.Contrat de service complet

Options de financement:
Available through our partners including equipment leasing,
operational leasetoown structures,
and project financing tailored for major capital expenditure

8.FAQ

Q1.Is the JC5000 compatible with my existing plant feed system( apron feeder/vibrating grizzly)?
A1.The JC5000 requires proper feed regulation but is designed to interface with standard industrial feeding equipment.Critical dimensions are provided early in the specification process

Q2.What is the expected operational costperton for wear parts?
A2.Costperton varies based on material abrasiveness.In comparable granite applications,the Quarry+ die design has demonstrated costs 2030% lower than previous generation jaws.Field data is available upon request

Q3.How does the hydraulic toggle system affect routine maintenance?
A3.It simplifies it.The system eliminates mechanical springs/shims reducing inspection points.Lubrication requirements are centralized.Routine tasks focus primarily on die condition monitoring

Q4.What training is provided for our maintenance crew?
A4.A comprehensive twoday onsite training program covers safe operation daily inspections routine maintenance procedures basic troubleshooting specific to this machine's systems

Q5.Are there financing options that align payback periods with projected efficiency gains?
A5 Yes.We offer structured finance solutions where repayment schedules can be modeled against typical efficiency gains(energy savings extended wear life increased throughput)

Q6.Can you provide sitespecific foundation drawings?
A6.Upon order confirmation we provide detailed certified foundation drawings including all loading data anchor bolt locations necessary for your civil engineering team