1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit's profitability? For plant managers and engineering contractors, the gyratory crusher is a critical asset where failures have exponential consequences. Common challenges include:
Unscheduled Downtime: Bearing failures or mainshaft issues can halt entire processing lines for days, costing hundreds of thousands in lost production.
High Maintenance Costs: Frequent, laborintensive liner changes and component wear directly impact maintenance budgets and manpower allocation.
Inconsistent Throughput: Poor feed distribution or worn crushing surfaces lead to product gradation fluctuations, downstream bottlenecks, and reduced overall plant efficiency.
Energy Inefficiency: Older or poorly optimized designs consume excessive power per ton of processed material, a fixed cost that directly affects operating margins.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The answer lies in a purposeengineered gyratory crusher from a dedicated private label manufacturer focused on R&Ddriven performance.

2. PRODUCT OVERVIEW

This product is a highcapacity primary gyratory crusher, engineered for private label partners who require robust, applicationspecific solutions for largescale mining and aggregate operations. Its design focuses on delivering maximum availability and optimal reduction ratios for hard, abrasive ores and rock.

Operational Workflow:
1. Feed Acceptance: Oversize material from haul trucks or loaders is directed into the steepsided feed hopper.
2. Crushing Action: The hydraulically adjusted mainshaft assembly gyrates within the concave liners, applying compressive force to reduce material size.
3. Discharge: Crushed product exits through the discharge opening at the bottom of the crushing chamber, with size controlled by the hydraulic setting adjustment system.
4. Material Handling: The product is conveyed to downstream secondary crushing or screening circuits.

Application Scope & Limitations:
Scope: Ideal for hightonnage (2,000+ TPH) primary crushing applications in metal ore mines (copper, iron, gold), large quarries producing aggregate, and major construction projects requiring onsite primary reduction.
Limitations: Not suitable for lowtonnage operations (<500 TPH), recycling applications with high tramp metal content without extensive protection systems, or portable/mobile plant installations due to size and weight.

3. CORE FEATURES

Patented Concave Profile | Technical Basis: Optimized crushing chamber geometry based on discrete element modeling (DEM) | Operational Benefit: Delivers a consistent chokefed crushing action for uniform wear and stable product gradation | ROI Impact: Extends liner life by an average of 1520%, reducing liner cost per ton and changeout frequency

Integrated Smart Bearing System | Technical Basis: Multisensor monitoring of bearing temperature, vibration, and lubrication pressure | Operational Benefit: Provides early warning diagnostics to prevent catastrophic bearing failure | ROI Impact: Eliminates unplanned downtime events related to bearing issues, protecting millions in potential production losses

Hydraulic Setting & Overload Protection | Technical Basis: Dualfunction hydraulic cylinder for precise CSS adjustment and automatic relief under uncrushable material | Operational Benefit: Allows operators to adjust product size remotely and protects the crusher from mechanical damage | ROI Impact: Reduces setting time by 70% compared to manual systems and prevents costly repairs from tramp steel events

TopService Design Philosophy | Technical Basis: All routine service tasks (liner changes, spider arm refurbishment) accessible from above | Operational Benefit: Eliminates the need for personnel to work beneath suspended components or dismantle the crusher structure | ROI Impact: Cuts scheduled maintenance downtime by up to 50%, enhancing plant availability

Direct Drive & Torque Limiter System | Technical Basis: Lowspeed synchronous motor coupled via an air clutch with torque limiter | Operational Benefit: Provides smooth startup under load capability and protects drive train from shock loads | ROI Impact: Reduces electrical stress during startup by 60% versus VFDonly solutions, lowering peak demand charges

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | This Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Mechanical Availability (Target) | 92 94% | >96% (Contractual Target) | +24 percentage points |
| Liner Life (Abrasive Ore) | ~6 Months (Varies) | 78 Months (Average Field Data)| +1520% Improvement |
| Specific Energy Consumption (kWh/t) ~0.8 1.2 kWh/t ~0.7 0.9 kWh/t ~1015% Improvement |
| CSS Adjustment Time <4 Hours 75% Faster |
| Total Cost of Ownership (5Year Projection)| Baseline Model Averages +1218% Lower TCO |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 10,000 metric tons per hour (tph), depending on model size and feed material.
Motor Power: Standard drives from 450 kW up to 1 MW+; engineered to client specifications.
Feed Opening: Gape sizes from 1,300 mm to 1,800 mm available.
Material Specifications:
Main Frame & Head Center: Highstrength cast steel alloy.
Concaves & Mantle Liners: Manganese steel alloys; optional premium alloys for specific abrasion/impact conditions available.
Main Shaft: Forged alloy steel with precision machining.
Physical Dimensions & Weight: Significant footprint; exact dimensions provided per model. Approximate installed weights range from 350 tonnes to over 800 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C with appropriate lubrication systems; dust sealing standard.

6. APPLICATION SCENARIOS

Copper Mine Expansion

Challenge A Tier1 copper operation needed to increase primary circuit throughput by 25% without expanding their truck fleet or dump pocket footprint. Their existing crusher was a bottleneck with frequent linerrelated downtime.

Solution Implementation of our largestcapacity gyratory crusher model featuring the patented concave profile for higher reduction ratio in a single pass.

Results Throughput increased by 28%. Liner life improved from an average of approximately five months to sixandahalf months under identical ore conditions. Annual production targets were met three weeks ahead of schedule following commissioning.

Granite Quarry Primary Circuit Upgrade

Challenge A major aggregate producer faced volatile energy costs and high maintenance expenses on their aging primary crusher. Product consistency was also an issue affecting their premium product lines.

Solution A midrange gyratory crusher was selected with a focus on energy efficiency via direct drive optimization and superior chamber geometry.

Results Specific energy consumption decreased by an average of approximately twelve percent yearoveryear despite increased operating hours.The consistent gradation reduced recirculating load in secondary circuits by nearly eighteen percent.The quarry reported meeting tighter specification bands more reliably for key customer contracts.

7. COMMERCIAL CONSIDERATIONS

Our private label manufacturing model provides flexible commercial pathways tailored for OEMs and largescale endusers:

Pricing Tiers: Structured around core model size (feed opening), drive power rating,and level of standard automation.Control system integration is offered as either basic local control or full PLC/SCADA interface packages.

Optional Features & Upgrades: Key options include advanced predictive maintenance sensor suites,dust suppression ring kits,material level monitoring systems,and proprietary wearresistant alloy packages for liners.

Service Packages: Available service agreements range from basic technical documentation support through comprehensive multiyear performance contracts covering planned maintenance,inspections,and guaranteed parts availability with defined response times.

Financing Options: We work with established financial partners ableto structure leasing arrangements,tailored payment plans aligned with project milestones,and other financing solutions upon request.This facilitates capital budget planningfor our clients' projects.

8.FAQ

Q:What levelof engineering supportis provided duringthe integrationof thisgyratorycrusherintoan existingplantlayout?
A OurR&Dandapplicationengineeringteamsworkdirectlywithyourprojectengineersto reviewfoundationdesignsfeedanddischargearrangementsandinterfacingwithexistingconveyorsystemsWe providecomprehensivelayoutdrawingsforcesandloaddatato ensureproperintegration

Q:Canyourcrushersbeconfiguredtooperatewithautomationsystemssuppliedbyothervendors?
A YesThecorecrushercontrolsystemisdesignedwithstandardindustrialcommunicationprotocols(egOPCUAProfibusEthernet/IP)allowingforseamlessdataintegrationintoplantwideprocesscontrolandmonitoringsystems

Q:Whatisthetypicalleadtimefromordertocommissioningforastandardmodel?
A Leadtimesvarybymodelsizeandcustomizationbutgenerallyrangefrom12to18monthsforcompletecrushersupplyincludingengineeringmanufacturingfactorytestinganddeliverySchedulesareconfirmeduponprojectkickoff

Q:Aretheredocumentedcasesofretrofittingyourcrushingchambertechnologyintoexistinggyratorycrushersfromothermanufacturers?
A WhileourprimaryfocusisnewunitswehaveexecutedseveralsuccessfulmodernizationprojectsforcompatiblelegacycrushersTheseinvolvereplacingkeywearcomponentsandsometimeshydraulicsystemstodeliverperformanceimprovementsAcasestudyreviewcanbe provideduponrequest

Q:Whatdefinesthe"TotalCostofOwnership"advantageinyourcomparisons?
A OurTCOanalysisovera5yearperiodaccountsforinitialcapitalcostenergyconsumptionprojectedwearpartslifeandreplacementcostsscheduledmaintenancelaborhoursandexpectedavailabilitylossesFielddatafromsimilarenvironmentsformsthebasisfortheseprojections

Q:Doyouoffertestcrushingofcustomermaterialsamplespriorto purchase?
A YesWeoperateapilotscalecrushingfacilityandcanperformcomprehensivematerialtestworkincludingabrasivenessandcompressionstrengthanalysisto validatecapacitymodelingandliner liferecommendationsThisdataisincludedinourtechnicalproposal

Q:Whatarethestandardwarrantytermsforthemainmechanicalcomponents?
A Themainstructuralcomponents(mainframeheadcenter)mainshaftassemblyandbearingscarryastandardwarrantyof24monthsfromcommissioningor26monthsfromshipmentwhicheveroccurfirstsubjecttocorrectinstallationoperationasperourmanuals