1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are escalating operational costs and unpredictable downtime eroding your quarry's profitability? Pour les directeurs d’usine et les entrepreneurs en ingénierie, ballast production presents distinct challenges that directly impact the bottom line. Les points douloureux courants incluent:
Génération d’amendes excessives: Jusqu'à 1520% of processed material can fall below spec, turning potential revenue into waste stockpiles.
Consommation élevée de pièces d’usure: The abrasive nature of trap rock, granit, and basalt leads to premature liner and hammer failure, provoquant de fréquents, costly maintenance stops.
Inconsistent Product Cubicity: Poor particle shape in the final product reduces track bed stability and can lead to product rejection.
Inefficacité énergétique: Older crushing stages consume disproportionate power for the usable tonnage produced, inflating operational expenses.
Capacité inflexible: Fixed plants struggle to adapt to fluctuating demand, creating bottlenecks or underutilization.

Is your current setup equipped to maximize yield from every ton of feed while controlling maintenance costs and energy consumption? The right primary crushing equipment is the foundational answer.

2. APERÇU DU PRODUIT: ODM QUARRY PRIMARY JAW CRUSHER FOR BALLAST PRODUCTION

This product line focuses on heavyduty primary jaw crushers engineered specifically for highvolume ballast production from hard, abrasive feed materials. As an ODM (Fabricant de conception originale), we provide customized crushing solutions built to your precise operational parameters and site constraints.

Flux de travail opérationnel:
1. Réduction primaire: ROM (RunofMine) roche de carrière, typically up to 800mm in size, is fed into the crusher's robust vibrating grizzly feeder (VGFF VGF) section.
2. Présélection & Écrasement: Le VGF élimine les fines naturelles et contourne les matériaux subsize, diriger uniquement les roches surdimensionnées vers la chambre de concassage. The deep,symmetrical jaw chamber performs the initial compressive break.
3. Mise en forme du produit: The kinematics of the jaw plate motion are optimized to promote interparticle crushing, enhancing particle cubicity on the first pass.
4. Décharge & Transport: Crushed material is discharged at a consistent CSS (Réglage du côté fermé) onto the primary conveyor for transport to secondary screening and crushing stages.

Champ d'application & Limites:
Idéal pour: Concassage primaire de dur, roche ignée abrasive (granit, basalte) and dense limestone for railway ballast and construction aggregates.
Limites: Ne convient pas aux collants, claybound materials without prescreening/scalping. Feed size is constrained by crusher model inlet dimensions.

3. CARACTÉRISTIQUES PRINCIPALES

HeavyDuty Rolled Steel Frame | Base technique: Singlepiece, stressrelieved fabrication | Avantage opérationnel: Élimine les fissures de fatigue du cadre sous charge cyclique; provides stable platform for precision bearing alignment | Impact sur le retour sur investissement: Extended structural life exceeding 20+ years reduces capital replacement risk.

Géométrie de chambre optimisée & Cinématique | Base technique: ST/DT (Steep/Deeper Toggle) cavity design with aggressive nip angle | Avantage opérationnel: Augmente le débit jusqu'à 10% at same power draw; promotes better particle shape for downstream processing | Impact sur le retour sur investissement: Higher yield of inspec product per operating hour directly increases revenue.

Hydroset CSS Adjustment System | Base technique: Hydraulic cylinders support the toggle seat for safe setting adjustment | Avantage opérationnel: Closedside setting changes can be made in minutes under load or during clearing strokes, without manual shims | Impact sur le retour sur investissement: Réduit de plus les temps d'arrêt liés aux changements de taille de produit 80%, enhancing plant flexibility.

LongLasting Manganese Jaws with Clamp Systems | Base technique: Isovitric supergrade manganese steel with reversible design; mechanical clamp system for fast replacement | Avantage opérationnel: Jaw life increased by 2530%; changeout time reduced from days to a single shift | Impact sur le retour sur investissement: Lowers costperton for wear parts and significantly increases plant availability.

Integrated PreScreening Grizzly Feeder | Base technique: Boltin grizzly sections with adjustable slope and gap settings | Avantage opérationnel: Supprime jusqu'à 20% of fines prior to crushing chamber, reducing unnecessary wear and improving chamber efficiency | Impact sur le retour sur investissement: Directly lowers wear part consumption and power cost per ton of crushed material.

Système de graissage automatisé centralisé | Base technique: Programmable lubrication unit serving all key bearing points | Avantage opérationnel: Assure des intervalles de lubrification optimaux des roulements; prevents both under and overgreasing failures | Impact sur le retour sur investissement: Extends critical bearing service life by an average of 35%, preventing catastrophic downtime.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Moyenne) | ODM Quarry Jaw Crusher Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Temps de disponibilité) | ~8590% (programmé & arrêts imprévus) |> 94% (based on field monitoring data) |> +5% Amélioration |
| Coût d'usure par tonne (Roche Abrasive) $0.12 $0.18/tonne| 25% Réduction |
| Consommation d'énergie spécifique| Varie considérablement; older units > 0.8 kWh/ton @ CSS 150mm| 19% Réduction |
| Génération d'amendes (<22mm)| ~1822% of total feed| 30% Réduction |
| Product Flakiness Index (Cible 30% after primary stage| Consistently Improved Shape |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de la gamme de modèles: 400 1,800 tonnes par heure (TPH), depending on feed material and closedside setting.
Ouverture d'alimentation: De 1 000 mm x 650 mm à 1 500 mm x 1 200 mm.
Exigences d'alimentation: Drive motor from 90 kW jusqu'à 300 kW; total installed power including feeder hydraulics specified per model.
Spécifications matérielles: Cadre soudé à haute résistance (Acier S355JR); Isovitric manganese crusher jaws; forged alloy steel eccentric shaft with largediameter spherical roller bearings.
Dimensions physiques & Poids: Approximate weights from 35 tonnes à 120 tonnes; detailed layout drawings provided for foundation planning.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust sealing compliant with ISO standard levels; noise emissions designed below 105 dB(UN) aux postes opérateurs.

6. SCÉNARIOS D'APPLICATION

Carrière Hard Rock approvisionnant le projet ferroviaire national

Défi: A granite quarry needed to supply over 2 million tons of Type I ballast within a strict timeline but faced excessive wear costs and fines generation (>22%) from their existing primary crusher.
Solution: Implementation of a customconfigured ODM heavyduty jaw crusher with an integrated aggressive grizzly feeder profile optimized for their specific granite blend.
Résultats: Fines generation reduced to below spec at <14%. Wear part lifecycle extended by approximately28%. The project was completed ahead of schedule due to sustained throughput rates averaging12% above target.

Aggregate Producer Expanding into Rail Ballast Market

Défi: An established aggregate producer lacked a primary stage capable of producing the consistent cubicity required by rail authorities without excessive secondary recrushing.
Solution: Installation of an ODM jaw crusher with a specially engineered chamber profile focused on firstpass shape optimization.
Résultats: Final product Flakiness Index achieved directly after primary crushing met rail specification (<25%), reducing load on secondary cone crushers by approximately15%. This allowed reallocation of secondary capacityto other product lines.

7. CONSIDÉRATIONS COMMERCIALES

Our ODM approach provides structured commercial flexibility:

Niveaux de tarification des équipements: Based on model size/capacity range:
Niveau I (1200 TPH): Fully customized solutions with advanced monitoring packages included.

Fonctionnalités facultatives & Forfaits:
Advanced PLC automation package with loadregulation logic
Wear part monitoring sensors
Dust suppression system integration
Modular skidbase design for faster installation

Forfaits de services:
Basic Warranty Package
Comprehensive Service Agreement including scheduled inspectionsand parts discounts
Turnkey Installation & Assistance à la mise en service

Options de financement:
We work with international export credit agenciesand equipment financing partners t o offer leasetoown arrangements , mediumterm loans , or tailored rentalpurchase agreements t o align w ith your project cash flow .

8.FAQ

Q:What level o f customization i s possible w ith your ODM jaw crushers?
A.We can modify several parameters including feeder dimensions ,grizzly bar configuration ,discharge conveyor interface points ,and motor mounting positions t o ensure compatibility w ith your existing plant layoutand feed system .

Q.How does this equipment improve our overall plant efficiency beyond justtheprimary stage?
A.B y deliveringa more consistent ,cubicalproductatthefirststage,yoursecondaryand tertiarycrushers operate more efficiently .This reduces circulating loadsand improves finalproductyieldwhile loweringtotalplantpowerconsumption .

Q:What i sthetypical delivery lead timeforacustomized unit?
A.Forstandardmodels withinourTierI&IIrange ,lead timesaretypically1622weeksfromorderconfirmation .FullycustomizedTier IIIsolutionsrequire detailed engineeringand mayextendto28weeks .Proactive planningi srecommended .

Q.Arewearparts interchangeablewithothercrusherbrands?
A.No .Ourwearpartsaredesigned specificallyforourchambergeometryandkinematics t oensureoptimalperformanceand longevity .We providecomplete technicaldrawingsforinventory planning .

Q.What kindo f foundationi srequired ?
A.We providecomprehensivefoundationdrawingswitheachorderincludingallstaticand dynamicloaddata .Foundationsaretypicallyreinforcedconcrete ;our engineerscanreviewyoursitespecificplansuponrequest .

Q.Doyouoffertrainingforouroperatorsandmaintenancestaff ?
A.Y es.O nsiteoperationalandsafetytrainingduringcommissioningi sincludedwith everysale .Additionalmaintenancetrainingmodulesareavailableaspartofourservicepackages .

Q.Whatarethekeyfactorsin determiningthecorrectmodelsizeforourapplication ?
A.Capacityselectionisbasedonfourprimaryfactors :yourmaximumfeedsizematerialhardnessorBWI( BondWorkIndex ),desiredproductsize( CSS ),andrequiredhourlytonnage .Ourtechnicalteamwillanalyze yoursamplesandspecificationst orecommendtheoptimalmodel