1. PAINPOINT DRIVEN OPENING

Are you managing the recurring costs and operational bottlenecks associated with primary crushing and material sizing? Common challenges include:
High Wear Part Expenditure: Frequent replacement of hammers, liners, and impact aprons due to abrasive feed material, directly impacting your costperton.
Unscheduled Downtime: Unplanned maintenance stops to address wear or component failure, halting your entire processing line.
Inconsistent Product Gradation: Variable output sizes leading to recirculating loads, reducing overall system throughput and efficiency.
Limited Application Flexibility: A crusher that cannot handle a range of materials or moisture contents forces compromises in your feed strategy.

How do you reduce total cost of ownership while maintaining reliable throughput and product quality? The solution lies in selecting a fabricated impact crusher engineered not just to crush, but to endure.

2. PRODUCT OVERVIEW: FABRICATED IMPACT CRUSHERS

A fabricated impact crusher is a robust reduction machine utilizing highspeed rotors and durable impact elements to fracture material through kinetic energy. Its design is characterized by a heavyduty, welded steel frame (fabrication) that provides the structural integrity for demanding primary or secondary crushing duties.

Operational Workflow:
1. Feed Intake: Material is directed into the crushing chamber via a reinforced feed hopper and apron.
2. Acceleration & Impact: The highinertia rotor assembly hurls material against stationary impact aprons or curtains.
3. Size Reduction: Fracturing occurs through repeated impacts, either rockonrock (within the rotor cascade) or rockonapron.
4. Product Ejection: Sized material exits through the adjustable gap between the rotor and aprons, determining final product gradation.

Application Scope: Ideal for limestone, recycled concrete/asphalt, demolition debris, and other mediumtolow abrasiveness materials. Effective for producing a wellshaped, cubical product.

Key Limitations: Not typically suited for highly abrasive hard rock (e.g., granite, trap rock) as primary crushers without significant wear cost tradeoffs. Performance can be affected by very high moisture or clay content without proper configuration.

3. CORE FEATURES

HeavyDuty Fabricated Frame | Technical Basis: Allwelded steel plate construction with internal ribbing | Operational Benefit: Provides exceptional rigidity to withstand dynamic loads and vibration, extending bearing life and maintaining alignment | ROI Impact: Reduces structural fatigue failures, lowering longterm maintenance costs by minimizing framerelated issues.

Hydraulic Adjustment System | Technical Basis: Integrated hydraulic cylinders for apron positioning | Operational Benefit: Allows operators to adjust product size or clear blockages quickly from outside the machine | ROI Impact: Cuts adjustment time by over 70% compared to manual systems, increasing plant availability.

MultiFacet Rotor Design | Technical Basis: Rotor discs with replaceable locking wedges securing hammer pins | Operational Benefit: Enables quick rotation or replacement of hammers/blow bars without full disassembly; maintains rotor balance | ROI Impact: Reduces rotor service time by up to 50%, directly lowering labor costs and downtime.

Interchangeable Wear Components | Technical Basis: Standardized alloy steel castings for aprons, liners, and blow bars in various metallurgies | Operational Benefit: Allows you to select wear part material (e.g., martensitic steel, chrome iron) based on your specific feed material’s abrasiveness | ROI Impact: Optimizes wear life versus part cost, providing up to 30% longer service intervals when correctly specified.

Large Service Access Doors | Technical Basis: Hinged or sliding doors on the crusher housing | Operational Benefit: Provides safe, unobstructed access for routine inspection and maintenance tasks | ROI Impact: Improves technician efficiency during preventative maintenance checks by providing easier access points.

Direct Drive Coupling System | Technical Basis: Fluid coupling or Vbelt drive options connecting motor to rotor | Operational Benefit: Smooths startup torque peaks and provides inherent overload protection under tramp iron events | ROI Impact: Protects motor and drive components from shock loads, reducing electrical and mechanical failure risk.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Baseline | Our Fabricated Impact Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Part ChangeOut Time (Primary Hammers) | 812 Hours (Manual Shim/Bolt) | 34 Hours (HydraulicAssisted/Wedge System) | ~65% Faster |
| Structural Frame Durability (in HighVibration Apps)| Welded Frame with Minimal Reinforcement| Computermodeled stress analysis with internal ribbing & gussets| Field data shows 40% longer service life before weld fatigue |
| Product Shape (Cubicity Index) Secondary Crushing| Varies Widely; Average CI of ~0.7| Consistent CI of 0.80.85 via optimized apron/rotor speed design| ~15% More Cubical Product |
| Throughput per Installed HP (for Limestone)| 100120 TPH per 100 HP| 130150 TPH per 100 HP due to optimized chamber geometry & rotor dynamics| Up to 25% Higher Efficiency |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent from 150 TPH to over 800 TPH in primary applications.
Power Requirements: From 200 HP (150 kW) to 600 HP (450 kW), configured for either electric motor or diesel drive.
Rotor Specifications: Solid steel rotor with bolton discs; diameters from ~40” (1000mm) to ~60” (1500mm); widths matched to feed opening.
Material Specifications: Main frame fabrications from ASTM A36/A572 steel; wear components available in AR400 steel plate or highchrome cast iron alloys.
Physical Dimensions (Example Model): Feed Opening up to ~42” x ~48” (1065mm x1220mm); Machine weight approximately 25,000 – 55,000 lbs (1125 metric tons).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust seals standard; optional Arctic packages or highdust environment kits available.

6. APPLICATION SCENARIOS

Recycled Concrete Aggregate Production

Challenge: A recycling yard faced excessive wear costs from rebarcontaminated concrete and unpredictable downtime due to uncrushable material jams.
Solution: Implementation of a heavyduty fabricated impact crusher with hydraulic apron adjustment and a tramp iron relief system.
Results: Reduced unplanned downtime by 60% due to quick jam clearing. Wear part life increased by an average of 35% through optimal alloy selection for the application.

Limestone Quarry Secondary Crushing

Challenge: A quarry’s existing secondary circuit produced excessive fines (<5mm) while struggling with occasional claybound feed, causing throughput drops.
Solution Installation of an impact crusher configured with variable rotor speed control and a multistage apron configuration.
Results Achieved better product fraction control; reduced fines generation by approximately 20%. Throughput stabilized as the crusher handled occasional sticky material more effectively than the previous cone crusher setup.

7. COMMERCIAL CONSIDERATIONS

Our fabricated impact crushers are offered in three primary tiers:
1. Standard Duty Tier: For consistent, nonabrasive materials like clean limestone. Focuses on core reliability at an entry price point.
2. HeavyDuty Tier (Most Common): Includes features like hydraulic adjustment, enhanced wear packages, and heavier rotors for mixed/recycled materials and general quarry use.
3. Modular/Portable Plant Tier: Crushers integrated into wheeled or skidmounted frames with preengineered feed/discharge systems for mobile contracting.

Optional features include automated lubrication systems,
advanced bearing temperature monitors,
and different drive configurations
(fluid coupling vs Vbelt).

Service packages range from basic commissioning
to comprehensive annual inspection contracts
with guaranteed parts availability SLAs

Financing options include equipment leasing,
rentaltoown programs,
and projectbased financing solutions

8.FAQ

Q1:What is your typical Minimum Order Quantity?
Our standard MOQ is one unit per order However we offer tiered pricing structures that provide discounts on orders for multiple units which is common for large contracting firms equipping several sites

Q2 Can your fabricated impact crusher replace our existing jaw cone setup?
In many secondary reduction applications yes Field data often shows an impact crusher can provide sufficient reduction at a lower capital cost than adding a secondary cone It requires analysis of your current feed size desired product specs

Q3 How do you ensure compatibility with our existing plant conveyor sizes discharge heights?
We require key interface dimensions during quotation Our engineering team designs discharge hoods support structures fit within your specified envelope ensuring smooth integration

Q4 What is the expected operational cost per ton for wear parts?
This varies significantly based on material abrasiveness We provide detailed estimates using industrystandard abrasion indices For example operating on clean limestone may yield $010$020/ton while recycled concrete could be $025$040/ton

Q5 Do you offer performance guarantees?
Yes we provide guaranteed minimum throughput capacity based on agreedupon feed material specifications subject terms conditions outlined our commercial proposal

Q6 What is lead time from order placement delivery?
For standard heavyduty models lead time typically ranges between weeks depending current production schedule confirmed upon order placement Custom configurations require additional engineering time

Q7 What operator training provided?
We include comprehensive onsite operator maintenance training during commissioning covering safe operation routine checks basic troubleshooting procedures Documentation includes detailed parts manuals schematic diagrams