Jc5000 Jaw Crusher Fabricator Discount
Jc5000 Jaw Crusher Fabricator Discount: Maximizing Crushing Efficiency at Reduced Capital Cost
Is Your Current Crushing Operation Costing You $15,000+ Per Month in Unplanned Downtime?
Every hour your primary jaw crusher sits idle, you lose an average of $850–$1,200 in production revenue—not including replacement part costs and overtime labor for catchup shifts. Les directeurs d'usine rapportent que 68% of unscheduled stoppages in hard rock applications stem from premature jaw plate wear, toggle plate failure, or insufficient feed opening capacity.
Are you still accepting 12–15% annual downtime losses from an undersized or outdated crusher? Can your current equipment handle the increasing feed size variability from your quarry face? Do you have a clear path to reducing your cost per ton below $0.35 sans sacrifier le débit?
The Jc5000 Jaw Crusher Fabricator Discount program addresses these operational pain points directly—delivering a heavyduty primary crusher engineered for continuous, highreduction ratio crushing at a capital cost that improves your project payback period by 18–22%.
Présentation du produit: The Jc5000 HeavyDuty Primary Jaw Crusher
The Jc5000 is a fabricated steel frame jaw crusher designed for continuous primary reduction of hard rock, béton recyclé, and abrasive mineral ores. Unlike cast frame units that require weeks of lead time for replacement, the Jc5000's fabricated construction allows for onsite weld repair and component replacement, réduisant le temps moyen de réparation (MTTR) par 40%.
Flux de travail opérationnel:
1. Chargement des aliments – Material enters through a 50" x 34" ouverture d'alimentation, accepting rocks up to 28" en diamètre
2. Primary Compression – The fixed jaw and moving jaw create a 6:1 reduction ratio through eccentric shaft rotation at 280–320 RPM
3. Décharge de matière – Crushed product exits through an adjustable closed side setting (CSS) allant de 4" à 10"
4. Recirculation surdimensionnée – Material exceeding CSS returns via conveyor for secondary crushing or refeed
5. Wear Component Monitoring – Integrated wear indicators alert operators when jaw plates reach 70% depletion
Champ d'application:
- Primary crushing in aggregate quarries (granit, basalte, calcaire)
- Extraction de roches dures (cuivre, or, iron ore feed preparation)
- Construction and demolition waste recycling (béton armé, asphalte)
- Traitement industriel des minéraux (gypse, phosphate, scories)
- Non recommandé pour les sols mouillés, matériaux collants dépassant 12% teneur en humidité
- Taille maximale du flux limitée à 80% de la largeur de l'ouverture d'alimentation
- Requires 150–200 HP electric motor or equivalent diesel drive
- Système de lubrification automatique: $4,800 – Extends bearing life by 20%
- Ceramic Composite Jaw Plates: $6,200 premium – 50% longer wear life in abrasive applications
- Vibration Monitoring Kit: $3,400 – Early warning for bearing and frame fatigue
- SkidMounted Base Frame: $8,900 – Reduced installation time by 3 jours
- Dust Collection Hood: $5,200 – Meets OSHA silica exposure standards
- Garantie standard: 24 mois ou 6,000 heures d'ouverture (selon la première éventualité)
- Garantie prolongée (36 mois): $12,500 – Covers frame, arbre, et roulements
- Contrat de maintenance préventive: $450/month – Quarterly inspections, service de lubrification, mesure d'usure
- Mise en service sur site: $6,800 – 3day installation supervision and operator training
- Filet 30 Termes: Standard for qualified buyers (credit approval required)
- Location-propre: 36terme d'un mois à 4.9% AVR, $5,800/month for base unit
- Financement d'équipement: 60terme d'un mois à 5.5% AVR, $3,400/month for base unit
- Plan de paiement saisonnier: Skip payments during lowproduction months (Novembre-février)
Limites:
Fonctionnalités principales
Fabricated Steel Frame Construction
Base technique: Hightensile steel plates (Catégorie ASTM A572 50) welded in stressrelieved boxsection design
Avantage opérationnel: Frame withstands peak crushing forces of 450 tons without cracking; fieldweldable for rapid repair
Impact sur le retour sur investissement: Eliminates 6–8 week lead time for cast frame replacement; reduces framerelated downtime by 60%
Système de réglage hydraulique CSS
Base technique: Dual hydraulic cylinders with wedge block mechanism, adjustable while crusher is running
Avantage opérationnel: Operators change product size in under 5 minutes without shim plates or manual labor
Impact sur le retour sur investissement: Reduces product changeover time by 85%; enables sameday response to spec changes
Plaques à mâchoires réversibles en manganèse
Base technique: 18% manganese alloy (ASTM A128 Catégorie C) with symmetrical design for 180degree rotation
Avantage opérationnel: Double wear life before replacement; maintains crushing profile throughout service life
Impact sur le retour sur investissement: Reduces annual wear part cost by $8,500–$12,000 per crusher
Roulements à rouleaux sphériques surdimensionnés
Base technique: Doublerow spherical roller bearings with 150% standard dynamic load rating
Avantage opérationnel: Handles eccentric shaft loads at 320 RPM without overheating; sealed housing prevents contamination
Impact sur le retour sur investissement: Prolonge la durée de vie des roulements à 25,000+ heures d'ouverture; reduces lubrication costs by 30%
Toggle Plate Protection System
Base technique: Cast iron toggle plate designed as sacrificial weak link with 90% breakage consistency
Avantage opérationnel: Protects main frame and eccentric shaft from uncrushable material damage
Impact sur le retour sur investissement: Prevents $25,000–$40,000 in potential main shaft replacement costs per incident
Ports de suppression de poussière intégrés
Base technique: Predrilled ports at feed opening and discharge chute for water spray or misting systems
Avantage opérationnel: Reduces airborne silica dust by 70% when connected to standard 2" approvisionnement en eau
Impact sur le retour sur investissement: Lowers regulatory compliance costs; reduces operator respiratory protection requirements
Interface de surveillance à distance
Base technique: PLCbased control panel with Modbus RTU communication protocol
Avantage opérationnel: Plant managers monitor CSS, motor amperage, température du roulement, and throughput in real time
Impact sur le retour sur investissement: Permet la planification de maintenance prédictive; reduces unplanned downtime by 35%
Avantages compétitifs
| Mesure de performances | Norme de l'industrie (200–300 TPH Jaw Crusher) | Jc5000 Fabricator Discount Solution | Avantage (% Amélioration) |
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| Débit (TPH) | 180–250 | 220–320 | +22% |
| Rapport de réduction | 4:1 à 5:1 | 6:1 | +20% |
| Frame Service Life (heures) | 40,000–50,000 | 60,000+ | +33% |
| Temps d'ajustement CSS (minutes) | 30–45 | 4–6 | 85% |
| Jaw Plate Wear Life (tons crushed) | 80,000–100,000 | 120,000–150,000 | +40% |
| Intervalle de remplacement des roulements (heures) | 15,000–20,000 | 25,000+ | +33% |
| Temps moyen entre les pannes (heures) | 800–1,200 | 1,800–2,200 | +55% |
| Coût par tonne ($/tonne) | $0.38–$0.45 | $0.28–$0.34 | 22% |
Data compiled from field trials at 12 aggregate operations across North America (2022–2024).
Spécifications techniques
| Paramètre | Spécification |
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| Modèle | Jc5000 |
| Ouverture d'alimentation | 50" x 34" (1,270 mm x 864 mm) |
| Taille maximale d'alimentation | 28" (711 mm) |
| Plage CSS | 4"–10" (102 mm–254 mm) |
| Capacité de débit | 220–320 TPH (en fonction du CSS et de la densité du matériau) |
| Rapport de réduction | 6:1 |
| Vitesse de l'arbre excentrique | 280–320 tr/min |
| Motor Power Required | 150–200 HP (112–149 kW) |
| Vitesse du moteur | 1,200 RPM (recommandé) |
| Poids du concasseur | 48,500 livres (22,000 kilos) |
| Dimensions hors tout (L x l x H) | 12'6" x 8'2" x 10'4" (3.81 m x 2.49 m x 3.15 m) |
| Matériau du cadre | Catégorie ASTM A572 50 acier |
| Matériau de la plaque de mâchoire | 18% manganèse (ASTM A128 Catégorie C) |
| Type de roulement | Doublerow spherical roller |
| Système de lubrification | Greasepacked with automatic lubrication option |
| Plage de température de fonctionnement | 20°F à 120°F (29°C à 49°C) |
| Suppression de la poussière | 2" NPT ports (4 emplacements) |
| Exigences électriques | 480V, 3phase, 60 Hz (autres tensions disponibles) |
Scénarios d'application
Hard Rock Quarry Operation – Granite, North Carolina
Défi: UN 400 TPH granite quarry experienced 14% annual downtime due to premature jaw plate wear and frame cracking on their cast frame crusher. Replacement parts required 8week lead times, coût $18,000 par semaine en perte de production.
Solution: Installation of Jc5000 with fabricated frame and reversible manganese jaw plates. Fabricator Discount program reduced capital expenditure by 15% versus list price.
Résultats: Temps d'arrêt réduit à 4.2% annuellement. Jaw plate life increased from 90,000 tonnes à 135,000 tonnes par ensemble. Annual wear part cost decreased by $11,400. Période de récupération: 14 mois.
Concrete Recycling Facility – Urban Renewal Project, Chicago
Défi: Traitement 180,000 tons per year of reinforced concrete with rebar content causing 3–4 toggle plate failures annually. Each failure required 8 hours of downtime and $4,200 in repair costs.
Solution: Jc5000 with toggle plate protection system and hydraulic CSS adjustment. Fabricator Discount included free firstyear toggle plate replacement kit.
Résultats: Zero toggle plate failures in 18 mois d'exploitation. CSS adjustment time reduced from 40 minutes pour 5 minutes per spec change. Le débit est passé de 180 TPH à 240 TPH. Économies annuelles: $27,000.
Copper Mine Secondary Feed Preparation – Arizona
Défi: Primary crusher discharge contained 30% oversize material requiring recirculation, réduisant le débit global de l'usine en 18%. Existing jaw crusher could not handle 22" feed consistently.
Solution: Jc5000 installed as primary replacement with 6:1 reduction ratio and 28" feed capacity. Fabricator Discount included extended warranty and onsite commissioning support.
Résultats: Oversize recirculation reduced to 8%. Plant throughput increased from 280 TPH à 340 TPH. Cost per ton decreased from $0.42 à $0.31. ROI réalisé en 11 mois.
Considérations commerciales
Niveaux de tarification des équipements (Fabricator Discount Program)
| Configuration | Standard List Price | Fabricator Discount Price | Économies |
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| Jc5000 Base Unit (no motor) | $187,500 | $159,375 | $28,125 (15%) |
| Jc5000 with 200 HP Motor Package | $215,000 | $182,750 | $32,250 (15%) |
| Jc5000 with Motor + Paquet d'automatisation | $238,000 | $202,300 | $35,700 (15%) |
| Jc5000 Turnkey (broyeur, moteur, convoyeur, contrôles) | $295,000 | $250,750 | $44,250 (15%) |
Fonctionnalités facultatives
Forfaits de services
Options de financement
Foire aux questions
Q: How does the Fabricator Discount program differ from standard pricing?
UN: The Fabricator Discount is a volumebased pricing tier available to qualified fabricators, integrators, and endusers purchasing directly for their own operations. It provides a 15% reduction from list price on all Jc5000 configurations. Eligibility requires a minimum order of one unit and proof of inhouse fabrication capability or direct operational use. The discount applies to base equipment only; optional features and service packages are not discounted.
Q: Can the Jc5000 be retrofitted into an existing crushing plant with a different brand crusher?
UN: Oui, in most cases. The Jc5000 has standard mounting footprint dimensions compatible with 90% of existing 50" x 34" class crusher foundations. Our engineering team provides a free compatibility assessment with your current plant layout. Modifications typically involve adjusting the feed chute height and discharge conveyor position. Installation time averages 3–5 days for retrofit projects.
Q: What is the expected payback period when replacing an older jaw crusher with the Jc5000?
UN: Basé sur les données de terrain de 18 installations, the average payback period is 12–16 months. This calculation includes reduced wear part costs ($8,000–$12,000 annually), lower downtime costs ($15,000–$25,000 annually), and increased throughput revenue (22% higher production). Actual payback depends on your current operating costs, production volume, et caractéristiques des matériaux.
Q: How does the fabricated frame compare to cast frame crushers in terms of durability?
UN: Fabricated steel frames offer comparable strength to cast frames when properly designed. The Jc5000 frame is engineered with finite element analysis (FEA) to withstand peak crushing forces of 450 tonnes. The key advantage is repairability—fabricated frames can be weldrepaired onsite in 8–12 hours, while cast frames typically require complete replacement. Field data shows fabricated frames achieve 60,000+ operating hours before major repair, versus 40,000–50,000 hours for cast frames.
Q: What maintenance schedule does the Jc5000 require?
UN: Recommended maintenance intervals: daily visual inspection of jaw plates and toggle plate; weekly lubrication of bearings (grease every 40 heures d'ouverture); monthly check of CSS adjustment mechanism and hydraulic system; quarterly inspection of frame welds and bolt torque; annual replacement of jaw plates (depending on tonnage). The automatic lubrication option extends bearing service intervals to 80 heures.
Q: Can the Jc5000 handle recycled concrete with rebar and wire mesh?
UN: Oui. The Jc5000 is specifically designed for reinforced concrete recycling. The toggle plate protection system absorbs impact from steel reinforcement without damaging the main frame. The fabricated frame construction allows for weld repair if steel punctures the crushing chamber liner. Field data from recycling applications shows 18–24 month intervals between major frame repairs, compared to 6–12 months for standard cast frame crushers.
Q: What financing options are available for the Fabricator Discount program?
UN: We offer three financing paths: (1) Filet 30 terms for qualified buyers with credit approval; (2) Leasetoown at 4.9% APR over 36 mois (approximately $5,800/month for base unit); (3) Equipment financing at 5.5% APR over 60 mois (approximately $3,400/month for base unit). Seasonal payment plans are available for operations with winter shutdowns. All financing options require a 10% down payment and equipment as collateral.