Stone Crusher Machine Fabricator Competitive Price
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent les marges de votre projet? Pour les directeurs d’usine et les spécialistes des achats, the core crushing stage is often the primary bottleneck. Les défis courants liés aux concasseurs de pierres sous-optimaux comprennent:
Usure excessive & Component Failure: Premature wear on liners, mâchoires, or cones leads to frequent, unplanned stoppages for replacement, costing thousands in parts and lost production daily.
Sortie incohérente & Contamination du produit: Poor crushing chamber design or unstable operation results in offspec product gradation, increasing recirculation load and reducing saleable material yield.
Consommation d'énergie élevée: Inefficient drive systems and poor power utilization directly inflate your kWhperton cost, a significant variable in highvolume operations.
Difficult Maintenance & Risques pour la sécurité: Complexe, timeconsuming maintenance procedures require extended downtime and expose technicians to unnecessary hazards during liner changes or clearing blockages.
Infrastructure Rigidity: Les concasseurs fixes manquent de mobilité pour les projets multisites, while poorly designed mobile units compromise on stability and throughput.
Is your current equipment delivering predictable tonnage at a controlled cost per ton? The solution requires a machine engineered not just to crush rock, but to crush operational inefficiency.
2. APERÇU DU PRODUIT
The FabriCore HD Series Jaw Crusher is a heavyduty, primary crushing station engineered for highabrasion quarrying, exploitation minière, et applications de recyclage par démolition. It is designed as a robust, stationary solution for operations prioritizing maximum uptime and lowest costperton over mobility.
Flux de travail opérationnel:
1. Consommation alimentaire: Oversized raw feed (ROM) is delivered via dump truck or loader into the vibratory grizzly feeder.
2. Réduction primaire: Material enters the deep crushing chamber where a powerful elliptical jaw motion applies compressive force against a fixed jaw plate.
3. Contrôle des gradations: Le matériau broyé sort par une ouverture de décharge réglable (CSS), determining the maximum product size.
4. Décharge & Transport: Sized material is discharged onto the integral product conveyor for transport to secondary processing or stockpiling.
Champ d'application: Idéal pour le hard rock (granit, basalte), minerai abrasif, and reinforced concrete demolition debris. Suited for fixedplant installations with expected annual production exceeding 500,000 tonnes.
Principales limites: Not designed as a mobile trackmounted unit. Requires stable concrete foundation and appropriate feed system engineering. Maximum recommended feed size is 85% de la dimension de l'ouverture d'alimentation.
3. CARACTÉRISTIQUES PRINCIPALES
Monoblock Fabricated Frame | Base technique: Highstrength, welded steel construction with finite element analysis (FEA) optimisation | Avantage opérationnel: Eliminates stress points and frame fatigue cracking common in bolted designs; ensures longterm alignment of crushing components | Impact sur le retour sur investissement: Réduit les coûts de réparation structurelle d’environ 60% over the crusher's lifespan; extends service life beyond industry average.
Système d'entraînement hydrostatique | Base technique: Direct hydraulic drive with variable displacement motors | Avantage opérationnel: Provides smooth startup under full load, reversible operation for clearing blockages, and infinite CSS adjustment under load | Impact sur le retour sur investissement: Lowers peak electrical demand; reduces mechanical transmission wear; increases operational availability by enabling quick clearing of stalls.
Toggle System with Pressure Relief | Base technique: Hydraulic toggle cylinder with integrated nitrogen accumulator overload protection | Avantage opérationnel: Automatically releases tramp metal or uncrushables without shearing pins or requiring manual intervention | Impact sur le retour sur investissement: Prevents catastrophic damage to other components; field data shows a reduction in tramp ironrelated downtime by over 90%.
Liner Lifetime Optimization | Base technique: Computeraided chamber profile design and reversible/interchangeable manganese steel liners | Avantage opérationnel: Promotes interparticle crushing for better shape; allows use of both liner ends before replacement; simplifies inventory | Impact sur le retour sur investissement: Increases liner life by 1530%; reduces consumable costs per ton crushed.
Point de graissage centralisé | Base technique: Singlepoint connection to a network of lubrication lines for all major bearings | Avantage opérationnel: Permet de sécuriser, rapid greasing during scheduled stops without dismantling guards; ensures consistent bearing protection | Impact sur le retour sur investissement: Cuts routine lubrication service time by half; extends critical bearing service intervals.
Support moteur intégré & Garde-ceinture | Base technique: Factoryaligned motor base and fully enclosed,
bolton belt guard assembly | Avantage opérationnel: Eliminates field alignment issues; provides superior operator safety and contains dust around the drive | Impact sur le retour sur investissement: Reduces installation/commissioning time; minimizes risk of injuryrelated stoppages.
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Norme de l'industrie (Competitive Jaw Crusher) | FabriCore HD Series Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Temps de changement de doublure| 1824 heures (temps d'arrêt) | < 12 heures (temps d'arrêt) | ~45% faster |
| Consommation d'énergie| Fixed speed motor / Entraînement par courroie trapézoïdale| Hydrostatic direct drive with loadsensing control| Jusqu'à 12% kWh/tonne inférieur |
| Tramp Iron Recovery Time| Manual pin removal / cutting torch (24 heures)| Hydraulic toggle reversal from operator station (<10 minutes)| ~95% faster |
| Frame Structural Warranty| 13 years standard warranty on frame/weldments| Lifetime warranty against defects in materials/workmanship| Definitive longterm assurance |
| Disponibilité (Temps de disponibilité)| Industry target ~8590% (estimé)| Fieldreported >94% in comparable applications| ~5% absolute increase |
5. SPÉCIFICATIONS TECHNIQUES
Model Featured: FabriCore HD4862
Ouverture d'alimentation: 48" x 62" (1200mm x 1500mm)
Taille maximale d'alimentation: 41" (1050mm)
Réglage du côté fermé (CSS) Gamme: 6" 14" (150mm 350mm)
Plage de capacité (@ defined CSS): 450 1,200 STPH (dépend de la matière première & gradation)
Exigence de puissance d'entraînement: Finale de niveau IV / Stage V compliant diesel engine OR electric motor option:
Electric Motor Option: 300 HP (225 kW), 460V/60 Hz/3Ph
Poids total (Broyeur + Mangeoire + Conveyor): Environ. 185,000 livres (84,000 kilos)
Spécifications des matériaux clés:
Frame Steel: ASTM A572 Grade 50
Jaw Liners: Acier au manganèse austénitique (14%18%)
Main Shaft Forging: Highalloy steel, ultrasonic tested
Bearing Housings: Cast ductile iron
Plage de fonctionnement environnementale: 20°C à +50°C (4°F à +122°F). Dust suppression kit recommended for arid environments.
6. SCÉNARIOS D'APPLICATION
Granite Quarry Primary Crushing Station
Défi:
A southeastern US granite quarry faced recurring frame weld failures on their primary jaw crusher after just four years of service. Unplanned downtime for repairs exceeded two weeks annually alongside high energy costs from an inefficient drive system.
Solution:
Replacement with a FabriCore HD4862 Jaw Crusher featuring the monoblock fabricated frame and hydrostatic drive system.
Résultats:
Zero structural issues reported after five years of operation. Energy monitoring showed an average reduction of $18 per operating hour in power costs at peak rates. Annual availability increased from approximately $86\%$ à $95\%$.
Urban Demolition Recycling Hub
Défi:
A contractor processing reinforced concrete from urban demolition struggled with frequent stallouts due to uncrushable rebar mats embedded in slabs. Each event required a full shutdown and dangerous manual torchcutting work inside the chamber.
Solution:
Installation of a FabriCore HD3650 Jaw Crusher equipped with the hydraulic toggle pressure relief system.
Résultats:
The system automatically detects overloads and reverses to eject uncrushables within one minute via remote control from the operator cabin. This eliminated an average of three manual interventions per week—reducing safety risk—and increased daily throughput by preventing extended stoppages.
7. CONSIDÉRATIONS COMMERCIALES
Our pricing structure is based on transparent configuration:
Niveau d'équipement de base ($XXXk $XXXk): Includes core FabriCore HD crusher with standard manganese liners,
electric motor drive option,
et contrôles de base.
Optional Feature Packages:
Paquet d'automatisation ($XXk): Includes CSS adjustment via PLC,
capteurs de surveillance de l'usure,
remote diagnostics port.
Ensemble anti-abrasion robuste ($XXk): Upgraded liner alloys,
additional wear plates at critical impact points,
ceramiclined feed chute sections.
Service Agreements:
1.Planned Maintenance Plan ($Xk/year): Inspections programmées,
lubrication kits,
priority technical support.
2.Comprehensive Uptime Plan ($XXk/year): Includes all planned maintenance plus discounted parts pricing up to $40\%$ off list price,
guaranteed emergency parts dispatch within $24$ heures.
Financing Options are available through our industrial partners including operating leases ($36$60 termes du mois),
prêts d'équipement,
and leasetopurchase agreements designed to preserve capital expenditure budgets.
(Note: Specific pricing figures are omitted here as they vary based on final specification,
currency region,
et les conditions du marché.)
8\. FAQ\\\\\\\\\\\\\\\\n\n\Q1\. How does this machine integrate into my existing plant flow\? \\nA\. The FabriCore HD Series is designed as a modular primary station\. We provide detailed interface drawings \(feed height\, discharge height\, footprint\, power connection points\) during the quotation phase\. Our engineering team can review your existing layout to ensure compatibility\.
\Q2\. What is the expected operational cost per ton crushed\? \\nA\. While site\specific\, industry testing demonstrates that operators typically achieve between \$10\%\15\%\$ lower total cost\per\ton compared to previous generation jaw crushers\. This stems from reduced energy consumption\, longer liner life\, higher availability\.
\Q3\. Are spare parts readily available internationally\? \\nA\. Yes\. We maintain regional inventory hubs on three continents\. For critical wear parts \(liners\) we guarantee stock availability against your serial number upon request\.
\Q4\. What training do you provide for our maintenance crew\? \\nA\. We include comprehensive onsite commissioning training covering operation\, daily checks\, routine maintenance procedures like greasing \,liner change protocols using our tooling system\.
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