White Label Impact Crushers Factory
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent vos marges de production globales? Pour les directeurs d’usine et les entrepreneurs, the performance of a primary impact crusher directly dictates profitability. Les défis courants incluent:
Coûts élevés des pièces d’usure: Frequent replacement of blow bars and wear liners halts production and creates significant, recurring expense.
Temps d'arrêt imprévus: Unplanned maintenance for wear part changes or component failure disrupts entire material flow schedules.
Gradation du produit incohérente: Les fluctuations des matières premières peuvent conduire à des produits hors spécifications., resulting in recrushing or rejected loads.
Flexibilité d'application limitée: A crusher that cannot efficiently handle a range of materials (par ex., béton recyclé, asphalte, calcaire) limits business opportunities.
Consommation d'énergie excessive: Inefficient crushing chambers and drive systems inflate your perton operating cost.
La question centrale est: comment obtenir une cohérence, highvolume reduction with lower costperton and greater operational control? The answer lies in the engineering priorities built into a modern white label impact crusher.
2. APERÇU DU PRODUIT
A white label impact crusher is a heavyduty, impacteur à arbre horizontal (HSI) designed for primary and secondary reduction of aggregates, béton, asphalte, et minéraux industriels. Engineered for private labeling by equipment distributors, it provides core OEMlevel performance with configurable branding.
Flux de travail opérationnel:
1. Consommation alimentaire: Material is loaded into a large capacity feed hopper, directed onto an adjustable primary feeder apron.
2. Accélération & Impact: Le matériau pénètre dans l'ensemble de rotor robuste, where it is accelerated by massive hammers (barres de soufflage) and hurled against adjustable primary and secondary impact aprons (rideaux).
3. Contrôle de la taille & Recirculation: Crushed material exits through the adjustable gap between the rotor and the aprons. Oversize material can be recirculated via a return conveyor for closedcircuit operation.
4. Décharge du produit: Sized aggregate is discharged onto the main product conveyor for stockpiling or further processing.
Champ d'application & Limites:
Portée: Idéal pour le calcaire, béton recyclé & asphalte (RCA), débris de démolition, scories, and other mediumtohard abrasives. Effective in both stationary plants and mobile tracked configurations.
Limites: Not suitable for highly abrasive igneous rock (par ex., granit, piège à pierres) as a primary option without accepting higher wear costs. Less effective than compression crushers (jaws/cones) for producing slabby products.
3. CARACTÉRISTIQUES PRINCIPALES
Système de réglage hydraulique | Base technique: Centralized hydraulic cylinders controlling apron positioning | Avantage opérationnel: Permet aux opérateurs d'ajuster la gradation du produit ou d'éliminer les blocages en quelques minutes à partir d'une station distante, sans changement manuel des cales | Impact sur le retour sur investissement: Réduit les temps d’arrêt des réglages jusqu’à 80%, augmentation de la disponibilité des plantes.
Conception de rotor monobloc | Base technique: Solid steel rotor disc forged from a single piece | Avantage opérationnel: Provides exceptional rotational mass for high inertia crushing and eliminates risks of disc separation under heavy load | Impact sur le retour sur investissement: Increases rotor service life by 23x versus bolted designs, reporter les coûts importants de reconstruction des immobilisations.
Système de pièces d'usure QuickChange | Base technique: Wedgelocked blow bars and toolless access doors | Avantage opérationnel: Enires blow bar sets can be reversed or replaced by a twoperson crew in under two hours | Impact sur le retour sur investissement: Cuts labor time per changeout by over 60%, réduisant directement les coûts de maintenance par heure de fonctionnement.
MultiPosition Aprons | Base technique: Primary and secondary aprons with multiple indexed positions even after wear | Avantage opérationnel: Maintains optimal impact angle and crushing chamber geometry as wear parts degrade, ensuring consistent product shape | Impact sur le retour sur investissement: Delivers more saleable product between wear part cycles, improving yield.
Boîtier de roulement robuste | Base technique: Spherical roller bearings housed in a rigid, singlepiece steel cartridge | Avantage opérationnel: Isolates bearings from frame stress and vibration; features integrated temperature sensors for condition monitoring | Impact sur le retour sur investissement: Prevents catastrophic bearing failure—a leading cause of extended downtime—enabling predictive maintenance.
Système d'entraînement direct | Base technique: Fluid coupling or Vbelt drive connected directly to the rotor shaft | Avantage opérationnel: Smooths startup torque peaks, protects the motor from shock loads, and allows for finetuning of rotor speed via sheave changes | Impact sur le retour sur investissement: Improves motor longevity and energy transfer efficiency under variable load conditions.
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Norme de l'industrie (EntryLevel HSI) | Solution de concasseur à percussion en marque blanche | Avantage (% amélioration) |
| : | : | : | : |
| Blow Bar Life (in RCA) | 15,000 20,000 tonnes par ensemble | 25,000 35,000 tons per set with optimized alloy & conception| +40% à +75% |
| Average Downtime per Wear Change| 46 heures (manual adjustment/shimming)| <2 heures (hydraulic adjustment/wedge lock)| 60% à 70% |
| Consommation d'énergie par tonne de production| Higher kWh/ton due to inefficient chamber design| Lower kWh/ton via optimized rotor kinetics & entraînement direct| Les données de terrain montrent 1015% amélioration |
| Cohérence de la forme du produit (Indice de cubique)| Variable with apron wear; requires frequent manual adjustment| Maintained within ±5% via multiposition aprons & hydraulic control| Significant reduction in offspec product |
5. SPÉCIFICATIONS TECHNIQUES
Plage de capacité: dépendant du modèle; depuis 150 TPH à 600+ TPH de granulats concassés.
Diamètre du rotor & Largeur: Du Ø1000mm x 1000mm au Ø1500mm x 2000mm.
Exigences de puissance du lecteur: Electric motor options from 200 kW (250 HP) à 500 kW (650 HP).
Taille de l'ouverture d'alimentation: Up to 1000mm x 1200mm to accept large feed material.
Spécifications des matériaux clés: Rotor constructed from hightensile steel forgings; barres de soufflage disponibles en plusieurs alliages (Chromium ceramic insert; Haute teneur en chrome; Acier martensitique); abrasionresistant steel liners throughout internal housing.
Dimensions physiques (Grand modèle typique): Environ. Longueur: 3.5m; Largeur: 2.8m; Hauteur: 2.5m (concasseur uniquement).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; roulements anti-poussière standard.
6. SCÉNARIOS D'APPLICATION
Béton recyclé & Asphalt Processing Plant | Défi: A midAtlantic recycling yard faced excessive wear costs from tramp metal in C&D debris and needed faster changeover times between concrete and asphalt crushing to meet tight project schedules.| Solution: Implementation of our white label impact crusher equipped with ultrawearresistant ceramic blow bars and the quickchange wedge system.| Résultats: Blow bar life increased by over 50%. Changeover time between material types reduced from one full shift to under two hours. This improved plant utilization by an estimated 18%, allowing more contract bids to be accepted.
Limestone Quarry Primary Crushing Circuit Upgrade Challenge An existing jawcone circuit was bottlenecked on peak demand days requiring higher primary throughput without increasing footprint or adding major conveyors Solution A highcapacity white label impact crusher was installed as the primary unit taking runofquarry feed replacing the jaw crusher Results Throughput increased by 30 due to higher reduction ratio in single pass Plant managers reported energy savings per ton compared to old twostage primary system
Portable Contract Crushing Fleet Challenge A contracting company needed uniform reliable performance across their fleet of portable crushing spreads to simplify operator training parts inventoryand maintenance forecasting Solution Standardization on three sizesof white label impactcrushersfor all theirtrackmountedplants Results Reduced parts inventorybycarrying commonwearparts across units Maintenance procedures became identical cutting training time Fleet uptime improved due tomore predictable service intervals
7 CONSIDÉRATIONS COMMERCIALES
Equipment pricing tiers are structured based on size capacityand standard feature sets providing optionsfrom baseline reliabilityto fully automated configurations
Les fonctionnalités optionnelles incluent
Hydraulic apron assistfor fine tuning
Advanced automation packagewith PLC controlfor liner wear monitoringand performance optimization
Dust suppression system integration kit
Specialty alloywear parts packagesfor specific materials
Forfaits de services disponibles
Standard warrantycovering partsand laborfor defined period
Extended protection plansfor major componentsrotor bearings
Onsite commissioningand operator training
Pre negotiated wear part kitswith guaranteed pricing
Financing Options White label impactcrushers canbe acquired throughcapital equipment loansoperating leasesor rental topurchase agreements tailoredto cash flow requirements
8 FAQ
Whatis themaximumfeed sizeformodel XLC300 The maximum recommendedfeed sizeis mmto ensure optimal performanceand protectthe rotorfrom excessive shockloads
Can thisimpactcrusher replacemyexistingjawcone circuit In manyaggregate andrecycling applications yes An HSIcan offerhigher reductionin onepass simplifyingthe circuit layout Operational data shouldbe reviewedto confirm suitabilityfor your specificmaterial
How doeshydraulic apron adjustmenttranslate topractical benefits It allowsyour operatorsto compensatefor wearmaintainproduct specand clearjams quicklyfrom groundlevel This directly reducesdowntimeandincreasesplant safety
Arewearparts readilyavailable givenitsa white labelproduct Yes Corewear partsblow barsapron linersare standardizedand manufacturedto common specifications Theyare heldin regionalstocking warehousesfor rapid delivery minimizingyour inventoryburden
Whatisthetypical leadtimefor delivery Standard modelsare typicallyavailable within weeksfrom order confirmation Customconfigurations mayrequire additional timebasedon optionalfeaturesselected
Do youprovideperformanceguarantees Yes we provide guaranteedcapacity ratingsbasedon defined feedmaterial characteristicsas wellas mechanical warrantyterms outlinedin the commercialagreement