1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gérez-vous l'augmentation des coûts et les goulots d'étranglement opérationnels de votre processus de réduction de taille? Pour les directeurs d’usine et les spécialistes des achats, the wrong hammer mill can manifest as persistent, profitdraining challenges:

Temps d'arrêt excessif & Coûts d'entretien: Frequent wear part replacement and unplanned stops for maintenance disrupt your entire production line. How much revenue is lost per hour of downtime?
Sortie incohérente & Qualité du produit: Fluctuations in particle size distribution and unwanted fines can compromise your final product specification, leading to batch rejections or reduced market value.
Consommation d'énergie élevée par tonne: Inefficient grinding mechanics directly translate to soaring electricity bills, a primary operational expense that erodes your margin.
Usure rapide dans les applications abrasives: Processing hard or abrasive materials can destroy standard hammers and liners in weeks, creating a cycle of high spare parts costs and labor.
Flexibilité limitée & Colmatage: Can your current equipment handle varying feed materials or moistures without frequent clogging, requiring manual intervention and safety risks?

La question centrale est: does your hammer mill act as a reliable asset for profit generation, ou un centre de coûts récurrents?

2. APERÇU DU PRODUIT

The industrial hammer mill is a core piece of impact crushing equipment designed for highvolume reduction of mediumhard to brittle materials. Its operational workflow is based on direct, highkineticenergy impact:

1. Consommation alimentaire: Raw material is uniformly fed into the grinding chamber via a controlled feeder.
2. Réduction de taille: Marteaux à rotation rapide (monté sur un rotor) frapper le matériau, le briser lors de l'impact avec les plaques de coupe.
3. Classification des particules: Sized particles pass through a screen (ou grille) with specific apertures determining the final maximum product size.
4. Décharge: Un matériau correctement dimensionné sort du broyeur, while oversized particles remain in the chamber for further reduction.

Champ d'application: Idéal pour le calcaire, gypse, charbon, granulats recyclés, verre, déchets de démolition, and certain minerals. Effective for both primary and secondary crushing tasks.

Principales limites: Ne convient pas aux travaux très durs (Mohs >6), ductile, or highly fibrous materials without significant modification and expect accelerated wear.

3. CARACTÉRISTIQUES PRINCIPALES

Équilibrage dynamique du rotor | Base technique: Computeraided dynamic balancing at operational RPM | Avantage opérationnel: Élimine les vibrations destructrices, prolonge la durée de vie des roulements jusqu'à 40%, allows for smoother fullcapacity operation | Impact sur le retour sur investissement: Reduces premature drive train failures, lowering longterm maintenance costs and associated downtime.

Réversible & Marteaux à bords MultiWear | Base technique: Symmetrical hammer design crafted from highchromium alloy steel | Avantage opérationnel: Hammers can be rotated or flipped 24 times to utilize all wear edges before replacement; doubles service life in abrasive applications | Impact sur le retour sur investissement: Directly cuts spare parts inventory cost and frequency of changeout labor.

Système d'écran QuickChange | Base technique: Hydraulic or manual slideout mechanism with segmented screen design | Avantage opérationnel: Changement d'écran terminé en moins 30 minutes contre plusieurs heures; enables rapid product size flexibility | Impact sur le retour sur investissement: Maximizes plant uptime and responsiveness to different production requirements or customer specs.

Châssis monobloc robuste | Base technique: Singlepiece fabricated steel base integrated with motor mount | Avantage opérationnel: Ensures perfect permanent alignment of motor and rotor shaft; prevents operational stress from misalignment | Impact sur le retour sur investissement: Eliminates a primary cause of belt wear and bearing failure, ensuring consistent power transmission.

Décharge assistée par air & Ports de dépoussiérage | Base technique: Integrated plenum designed for negative pressure connection | Avantage opérationnel: Actively removes finished material from the chamber, preventing recirculation and heat buildup; reduces internal wear and improves throughput by up to 15% | Impact sur le retour sur investissement: Réduit la consommation d’énergie spécifique (kWh/tonne) and improves mill efficiency.

DualFunction Breaker Plate | Base technique: Adjustable impact plate with replaceable carbide inserts in highwear zones | Avantage opérationnel: Optimizes impact angle for different materials; dramatically increases liner life in critical wear areas | Impact sur le retour sur investissement: Reduces costperton for liner consumables by providing targeted protection where it matters most.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de broyeur à marteaux Avantage documenté |
| : | : | : |
| Durée de vie des pièces d'usure (Matériau abrasif) | ~300400 Operating Hours
Standard Manganese Steel Hammers| ~7501000 Operating Hours
HighChrome Alloy Reversible Hammers| Jusqu'à 150% Amélioration |
| Consommation d'énergie spécifique
(kWh per metric ton) Varie selon le matériau.| Ligne de base = 100%| Field data shows consistent operation at 8590% of baseline consumption.| 1015% Gain d'efficacité |
| Temps de changement d'écran
(Procédure complète) Manual systems.| 2 3 Heures moyennes| Engineered quickchange system completes task in <30 minutes.| ~80% Time Reduction |
| Temps moyen entre les pannes (MTBF)
Critical Drive Components| ~4,000 Hours Typical| Dynamic balancing & aligned baseframe extend MTBF to >6,500 heures.| Sur 60% Amélioration |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Débit dépendant du modèle à partir de 5 TPH à plus 150 TPH for standard mineral applications.
Exigences d'alimentation: Driven by heavyduty electric motors from 75 kW à 500 kW+, configuré pour les normes de tension mondiales (380V480V / 5060Hz).
Spécifications des rotors: Solid forged or fabricated steel rotor with machined hammer pins; diameters from 800mm to 2000mm; widths matching feed opening.
Spécifications matérielles: Main housing constructed from ≥25mm thick mild steel plate. Highwear components offered in AR400 Steel, Fer à haute teneur en chrome (HiCr), or Tungsten Carbide overlays based on application.
Dimensions physiques (Exemple de modèle): Ouverture d'alimentation: 1400mm x 800 mm; Longueur totale: ~3200mm; Largeur: ~2800mm; Hauteur: ~2500mm; Environ. Poids: 18 Tonnes.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Dusttight housing rated for connection to dust collection systems meeting local emissions standards.

6. SCÉNARIOS D'APPLICATION

Préparation des matières premières d'une cimenterie | Défi: A plant processing limestone with high silica content faced hammer changes every three weeks (~500 hrs), causing costly kiln line stoppages every quarter for major maintenance.| Solution: Implementation of a heavyduty hammer mill with reversible HiCr hammers and tungstencarbide enhanced breaker plates.| Résultats: Hammer service life extended to nine weeks (~1500 hrs). Major maintenance intervals aligned with annual planned shutdowns, eliminating three unplanned stoppages per year and reducing crushing circuit spare parts cost by an estimated $65,000 annuellement.

Construction & Installation de recyclage des déchets de démolition | Défi: Composition alimentaire incohérente (béton, briques, asphalte) led to frequent screen clogging with damp material and rapid hammer wear at pivot holes causing premature failure.| Solution:: Installation of a hammer mill featuring an airassisted discharge system to handle moisture and hardened hammer pins with proprietary bushing design.| Résultats:: Throughput of mixed C&D waste increased by an estimated 20% due to eliminated clogging delays. Hammer change frequency reduced by 30%, directly lowering labor hours spent on maintenance.

7. CONSIDÉRATIONS COMMERCIALES

Our industrial hammer mills are offered in three primary tiers:

1. Série de service standard: For consistent feed materials like limestone/gypsum. Focus on reliability and costeffectiveness for singleapplication plants.
2. Série robuste: Engineered for abrasive materials (par ex., silicarich rock) featuring enhanced wear packages as standard.
3. Solutions conçues sur mesure: For unique applications such as metal recovery circuits or specific grain shape requirements involving modified rotors or specialized liners.

Les fonctionnalités optionnelles incluent:

Systèmes de lubrification automatisés
Vibration monitoring sensors
Explosionproof construction
Specialized screen geometries

We support commercial buyers through:
Comprehensive Service Packages ranging from basic commissioning to full annual inspection contracts with guaranteed parts availability.
Financement & Leasing Options available through partners to facilitate capital expenditure planning.

8.FAQ

1.Q:What information do you need to recommend the correct hammer mill model?
A.We require details on your target material(s) including hardness/abrasiveness analysis if available), required feed size input), desired output particle size distribution), target hourly capacity tons per hour), plage de teneur en humidité).

2.Q:What is the typical lead time?
A.For standard models within our HeavyDuty Series lead time is typically 1216 weeks FOB China port depending on current order volume Customengineered solutions require additional engineering time

3.Q:What are my options if my feed material characteristics change over time?
A.The reversible hammer design provides flexibility The quickchange screen system allows you adapt final product size We can also advise on retrofitting different liner materials postpurchase

4.Q:What warranty coverage do you provide?
A.We offer a standard 12month warranty against defects in materials workmanship starting from commissioning This excludes normal wear parts like hammers screens which are consumables

5.Q:Quel niveau de support technique est fourni lors de l'installation?
A.Commissioning supervision by our factory engineers is available either included within certain service packages or as an optional purchase We provide comprehensive operation maintenance manuals electrical schematics foundation drawings digitally prior shipment

6.Q.How do you ensure consistent manufacturing quality?
A.Every major assembly rotor housing undergoes documented inspection protocols including nondestructive testing NDT dynamic balancing reports Final testing includes noload runin at our facility before disassembly shipping

7.Q.Can you supply all necessary ancillary equipment?
A.We can provide complete system integration including feed conveyors magnetic separators structural steel supports dust collection interfaces electrical control panels as part turnkey project scope