1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the primary crushing stage is often the source of critical bottlenecks. Common challenges include:

Excessive Downtime for Maintenance: Frequent liner changes and unplanned repairs halt your entire processing line, costing thousands per hour in lost production.
High Wear Part Costs: Rapid abrasion of crusher components in hard rock or abrasive feed materials leads to unsustainable consumable expenses.
Inconsistent Output Gradation: Fluctuations in feed size or hardness result in poor product shape and offspec material, forcing recrushing or reducing saleable product value.
Energy Inefficiency: Older crushing technology consumes disproportionate power per ton of output, directly impacting your bottom line.
Rigidity to Feed Variations: The inability to handle occasional oversize material or varying moisture content causes blockages and system stress.

Is your primary crusher a constant source of operational friction and cost? What if your cornerstone equipment could deliver not just raw power, but predictable performance and lower costperton?

2. PRODUCT OVERVIEW

The Industrial Jaw Crusher is a heavyduty, compressiveforce primary crusher engineered for the first stage of size reduction in quarrying, mining, and demolition recycling operations. Its robust design is built to process the toughest materials, including granite, basalt, and recycled concrete.

Operational Workflow:
1. Feed Intake: Large runofmine or quarryrun material (up to 80% of crusher feed opening) is loaded into the vibrating grizzly feeder (optional) which bypasses fines directly to the downstream circuit.
2. Compressive Crushing: Material enters the fixed and movable jaw die cavity. The elliptical motion of the movable jaw applies immense compressive force, breaking particles against the stationary jaw.
3. Discharge Setting Adjustment: The crushed product size is precisely controlled by hydraulically or mechanically adjusting the gap at the discharge point (Closed Side Setting).
4. Discharge & Conveyance: Sized material exits at the bottom and is conveyed to secondary crushing or screening stages.

Application Scope & Limitations:
Scope: Ideal for highcapacity primary crushing of hard, abrasive materials. Suited for stationary plants and mobile tracked setups.
Limitations: Not designed for sticky, plastic materials without prescreening. Product shape is generally more angular compared to cone crushers; for final shaping, secondary crushing is typically required.

3. CORE FEATURES

Deep Crushing Chamber & Optimized Kinematics | Technical Basis: Enhanced nip angle and longer stroke at feed opening | Operational Benefit: Allows for larger feed size acceptance and delivers higher reduction ratios in a single pass | ROI Impact: Reduces need for preblasting or secondary sizing steps, lowering total cycle cost

HeavyDuty Frame Construction | Technical Basis: Fabricated from highgrade steel plate with reinforced stress points | Operational Benefit: Provides exceptional durability under maximum load conditions, resisting fatigue over decades of service | ROI Impact: Minimizes risk of catastrophic frame failure, protecting longterm asset value

Hydraulic Toggle Adjustment & Clearing System | Technical Basis: Replaces traditional mechanical toggle plates with hydraulic cylinders | Operational Benefit: Enables remote adjustment of CSS for quick product grading changes and automatic uncrushing/clearing of blockages | ROI Impact: Reduces downtime for adjustments by up to 70% and eliminates manual clearing hazards

Manganese Steel Jaw Dies with Interchangeable Profiles | Technical Basis: Austenitic manganese steel workhardens under impact for extended service life; reversible/rotatable designs | Operational Benefit: Maximizes wear material utilization before replacement; operators can match tooth profile to application (quarrying vs. recycling) | ROI Impact: Extends mean time between replacements by 3050%, directly lowering consumable inventory costs

Centralized Automated Greasing System | Technical Basis: Programmable lubrication unit servicing all key bearings via distribution lines | Operational Benefit: Ensures optimal bearing lubrication under all operating conditions without manual intervention | ROI Impact: Prevents premature bearing failure—a leading cause of major downtime—and reduces labor for daily maintenance checks

VBelt Drive with Flywheel Mass | Technical Basis: Highinertia flywheels store energy on the return stroke to smooth out power demand peaks | Operational Benefit: Maintains consistent crushing momentum under load fluctuations; reduces peak motor current draw | ROI Impact: Lowers energy consumption per ton crushed by an average of 1520% compared to directdrive systems without flywheels

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Competitor Averages) | Industrial Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime | 8590% (scheduled + unscheduled downtime) |> 94% availability documented over 5year period |> 5% improvement |
| Wear Part Cost per Ton (Abrasive Granite) | $0.45 $0.55 USD / ton crushed |> $0.32 $0.38 USD / ton crushed |> ~30% reduction |
| Energy Consumption (kW per Ton Output) ~Hard Rock~| ~1.8 2.2 kWh/ton |> ~1.5 1.7 kWh/ton |> ~20% improvement |
| CSS Adjustment Time (Mechanical vs Hydraulic)| Manual shim adjustment (~48 hours) |> Hydraulic adjustment ( Up to 90% faster |

5.TECHNICAL SPECIFICATIONS

Model Range & Capacity: JC1200 through JC1800 series; throughput from 450 MT/hr up to 1,600 MT/hr depending on feed material and CSS setting.
Feed Opening: Ranges from 1200mm x 830mm (47" x 33") up to 1800mm x 1400mm (71" x 55").
Power Requirements: Main crusher motor from 110 kW up to 400 kW (150 HP – 500 HP), dependent on model size.
Material Specifications: Main frame constructed from ST523 steel; jaw dies from premiumgrade Mn18Cr2 alloy steel; shaft from forged42CrMo4 alloy.
Physical Dimensions & Weight: Approximate installed weight ranges from ~45 tonnes (JC1200) to ~130 tonnes (JC1800). Detailed foundation plans provided.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C (4°F to +113°F). Dust sealing kits available for highdust environments.

6. APPLICATION SCENARIOS

Granite Quarry Primary Crushing Plant

Challenge:
A large granite quarry faced frequent liner changes every six weeks on their existing jaw crusher due to extreme abrasiveness, causing over two days of production loss each time alongside high parts costs.

Solution:
Implementation of an Industrial Jaw Crusher equipped with Mn18Cr2 jaw dies optimized for abrasion resistance.

Results:
Field data shows wear life extended by over two months between scheduled changes—a >60% increase in service life—reducing annual downtime by approximately ten days while cutting wear part costs by an estimated $95k annually.

Urban Construction & Demolition Waste Recycling

Challenge:
A C&D recycling facility struggled with unpredictable feed containing rebarreinforced concrete blocks causing regular jams in their primary crusher that required dangerous manual clearing operations.

Solution:
Deployment of a mobiletracked Industrial Jaw Crusher featuring a hydraulic toggle system with automatic release/reset functionality.

Results:
The hydraulic clearing system automatically dislodges tramp metal or uncrushables within minutes without operator intervention at the crusher inlet site safety incidents related to blockages were eliminated throughput increased by an average of eight truckloads per shift due to reduced stoppages.

7. COMMERCIAL CONSIDERATIONS

Our pricing structure reflects build quality engineering support:

Pricing Tiers
• Base Equipment Tier Includes core crusher standard motor drives basic tool kit
• ProductionReady Tier Adds integrated motor starter variable frequency drive automated greasing system dust suppression nozzles
• Turnkey Mobile Tier Complete tracked chassis independent prescreen hydraulic setting adjustment remote control capability

Optional Features
• Hydraulic wedge lock system for faster die changes
• Rock breaker mounting boss package
• Extended capacity hopper module
• Advanced condition monitoring sensors

Service Packages
• Standard Warranty Comprehensive coverage includes parts labor first year
• Extended Protection Plan Covers major components years two through five
• Annual Performance Contract Includes scheduled inspections wear part audits guaranteed OEM parts pricing priority technical support

Financing Options Available through our partners including equipment leasing longterm rental purchase plans tailored capital expenditure cycles typical terms range from three seven years subject credit approval

8. FAQ

Q What are my options if my existing plant uses a different brand secondary cone crushers?
A Our industrial jaw crushers are designed standard discharge conveyors integrate seamlessly any downstream circuit We provide detailed interface drawings ensure compatibility belt widths speeds chute designs Your existing screening secondary crushing equipment will function normally often more efficiently due consistent primary product gradation

Q How does this impact my overall plant efficiency?
A By providing stable predictable primary reduction you minimize downstream bottlenecks Field data shows plants experience fewer surges secondary circuits leading smoother operation overall higher final product consistency This stability allows optimization subsequent stages maximizing total plant output

Q What typical installation timeline commissioning period?
A For stationary units installation foundation preparation typically requires weeks depending site conditions Commissioning supervised our engineers takes days involves calibration safety checks performance testing achieve rated throughput We provide detailed project plan coordination your team minimize disruption

Q Are spare parts readily available globally?
A We maintain regional warehouse hubs North America Europe AsiaPacific ensuring critical wear parts bearings available within hours days not weeks Our online portal provides realtime inventory tracking direct ordering technical documentation download access authorized distributors worldwide network supports you locally regardless location purchase origin

Q Can this machine handle wet sticky claybearing materials effectively?
A While capable processing such materials we recommend prescreening scalping remove fines excess moisture prevent packing chamber For applications consistently high clay content we advise consultation our engineering team may recommend specific feeder modifications alternative primary crushing technology better suited those specific conditions