1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing unpredictable production bottlenecks and rising operational costs in your aggregate or mineral processing plant? Key challenges with secondary and tertiary crushing often include:

Kos Bahagian Pakai Tinggi & Downtime yang tidak dirancang: Penggantian tukul yang kerap, pelapik, and blow bars due to abrasive materials, leading to significant parts expenditure and production halts.
Penggredan Produk Tidak Konsisten: Fluctuations in feed material density or composition can cause unwanted fines or oversized product, failing to meet strict specification requirements for downstream processes or final product sales.
Penggunaan Tenaga Berlebihan: Older or inefficient impact crusher designs consume disproportionate power per ton of processed material, directly impacting your bottomline operating costs.
Fleksibiliti Aplikasi Terhad: A crusher that cannot be adjusted efficiently for different product sizes or material types forces operational compromises and limits plant versatility.

Is there a solution that delivers consistent product shape, reduces total cost of ownership through superior wear management, and provides the operational flexibility modern operations demand?

2. GAMBARAN KESELURUHAN PRODUK: HIGHPERFORMANCE EXPORT IMPACT CRUSHERS

Our line of exportready horizontal shaft impact (HSI) crushers is engineered for highvolume reduction of medium to lowabrasive materials such as limestone, konkrit kitar semula, asfalt, dan serpihan perobohan. These machines are central to aggregate production and recycling operations.

Aliran Kerja Operasi:
1. Kemasukan Suapan: Material is directed into the robust feed hopper and onto the adjustable feed chute.
2. Pecutan & Kesan: Material is struck by highvelocity rotating hammers (Bar Blow) mounted on a solid rotor assembly and hurled against the adjustable primary impact aprons (langsir).
3. Pengurangan Terkawal: Size reduction occurs through both initial impact and subsequent collisions between particles (rockonrock crushing within the chamber).
4. Pelepasan Produk & Saiz: Crushed material exits through the adjustable gap between the rotor and the aprons. A secondary apron/cage may be used for further refinement before discharge onto a conveyor.

Skop Permohonan & Batasan:
Sesuai Untuk: Batu kapur, dolomit, konkrit kitar semula/asfalt (Rap/Ras), pasir & Kerikil, arang batu, and similar materials with low to medium silica content.
Batasan: Tidak disyorkan untuk bahan yang sangat kasar (mis., granit, batu perangkap, kuarzit) as primary reduction units due to accelerated wear rates; these are better served by primary jaw or cone crushers.

3. CIRI TERAS

Sistem Pelarasan Hidraulik | Asas Teknikal: Silinder hidraulik terkawal komputer | Faedah Operasi: Allows operators to adjust the primary apron setting during operation for realtime product size control without stopping production. | Kesan ROI: Mengurangkan masa henti pelarasan sehingga 90%, meningkatkan kapasiti pengeluaran tahunan.

Reka Bentuk Komponen Pemakaian Modular | Asas Teknikal: Segmented wear plates and reversible/rotatable blow bars | Faedah Operasi: Enables partial replacement of worn sections and extends component life by utilizing multiple edges. Reduces maintenance time through simpler handling. | Kesan ROI: Menurunkan kos inventori bahagian haus dengan 2540% and reduces labor hours per changeout by an estimated 30%.

Solid Rotor vs. Open Disc Design | Asas Teknikal: Fabricated steel rotor with monolithic structure | Faedah Operasi: Provides superior inertia for crushing larger feed sizes and higher durability with fewer stress points compared to open disc rotors. Essential for heavyduty applications. | Kesan ROI: Meningkatkan masa min antara kegagalan (MTBF) for the rotor assembly, reducing major overhaul frequency and associated capital repair costs.

Geometri Dewan Lanjutan | Asas Teknikal: Optimized internal profiles derived from computational fluid dynamics (Cfd) analisis | Faedah Operasi: Improves material flow through the crushing chamber, reducing recirculation load and power surges while enhancing particleonparticle breakage for better cubicity. | Kesan ROI: Mencapai sehingga a 15% peningkatan dalam kecekapan tenaga (kWj/tan) compared to previousgeneration designs.

Pintu Penyelenggaraan QuickAccess | Asas Teknikal: Besar, hinged service doors with safety lockout provisions | Faedah Operasi: Menyediakan selamat, direct access to the interior chamber for inspection, blow bar rotation/replacement, and apron adjustment without major disassembly. | Kesan ROI: Cuts standard service intervals from hours to minutes directly translating to higher plant availability.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Our Export Impact Crusher Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Kos Pakai setiap Tan (Batu kapur) | $0.022 $0.035/ton | $0.016 $0.025/ton | Hingga 30% Pengurangan |
| Penggunaan kuasa (kW per 100 tph) ~250 kW / 100tph ~215 kW / 100tph ~14% Improvement in Efficiency |
| Indeks Kubisiti Produk (>20mm fraction) CI of 0.75 0.85 CI consistently >0 .88 Improved Aggregate Shape |
| Average Time for Apron Gap Adjustment Manual shim adjustment (~48 hrs) Sistem hidraulik (~2030 mins) ~90% Faster Adjustment |

5.SPESIFIKASI TEKNIKAL

Julat Kapasiti: Model boleh didapati daripada 150 ke 800+ tan sejam (Tph), bergantung pada ketumpatan bahan suapan dan tetapan saiz produk.
Diameter pemutar & Lebar: From Ø1300mm x 1200mm up to Ø2000mm x 2500mm configurations.
Drive Power Options: Pemacu motor elektrik terdiri daripada 250 kW kepada 800 kw , tailored to regional voltage standards (e.g.,50Hz /60Hz ,400V ,6 .6kV).
Saiz pembukaan suapan: Up t o1600mm x2500 mm maximum feed size capability .
Spesifikasi Bahan Utama :
Aci pemutar :Forged42CrMo steel ,diuji secara ultrasonik .
Perumahan : Fabricatedfromhigh yieldstrengthsteelplatewithinternalbolt onwearliners .
Bar Blow : Premium chromium ceramic composite alloys or martensitic steel options available .
Julat Suhu Operasi : Designedforambientoperationfrom20°Cto+45°Cwithappropriate lubrication systems .

6 .SENARIO APLIKASI

Aggregate Quarry Expansion Challenge A Midwest US limestone quarry needed t oincrease minus 1”baseproductproductionwithoutaddinganewcrushinglineorbudgetforfrequentdowntime .Solution Installationofahigh capacityexportimpactcrusherasasecondaryunitpost jawcrusher ,utilizingitshydraulicadjustmenttoshiftbetween1”and¾”productasneeded .Results Theplantachieveda22 %increaseinbaseproductthroughput .Wearcostsremainedstable despitehighertonnage ,andoperatorscouldmeetchangingdailyorderspecificationsinunderanhour .

Pembinaan &Perobohan(C&D )RecyclingFacility Challenge AnurbanC&Drecyclerfacedexcessivewearandunacceptablemetalliccontamination( rebar )intheirfinalaggregateproductfromanolderimpactcrusher .Solution Implementationofasolid rotorexportimpactcrusherequippedwithspecializedblowbarsto handlehighshockloadsandembeddedmetal .Thedesignincludedamagneticseparationconveyorpost crush .Results Contaminationinminus ¾”recycledaggregatefellbelow1 %byweight ,meetingstrictspecificationsfordrainageapplications .Blowbarlifeincreasedbyapproximately60 %despitetheabrasiveandunpredictablefeed .

7.PERTIMBANGAN KOMERSIL

Our export impact crushers are offered in three primary tiers :

Siri Tugas Standard : Forconsistent ,medium abrasivematerials(likepurelimestone ).Focusesoncore reliabilityandcapitalcostoptimization .
Siri Tugas Berat : Fortougherapplicationsincludingrecycledconcretewithhighercontaminantlevels .Featuresreinforcedcomponentsandsolidrotortechnologyasstandard .
Siri Tumbuhan Modular : Fullyintegratedskid mountedorsemi portableunitspre wiredandpipedforrapiddeployment ;includespresetfeedersandscreens .

Optional features include automatedgreasingsystems ,vibrationmonitoringpackages ,specializedwearlinermaterials( e.g.,ceramicinserts ),andenclosedwalkwaysforservice .

We offercomprehensiveservicepackagesfrombasiccommissioningtofullannualmaintenanceagreementswithguaranteedresponse times .Financingandleasingoptionsareavailablethroughpartnersto managedeploymentcapital .

8.Soalan Lazim

S1:Arewearpartsinterchangeablewithotherbrandsofcrushers ?
A1 No Ourexportimpactcrushersaredesignedwithproprietarymodularwearcomponentsforsuperiorperformanceandspecificbalancingrequirements Weguaranteeoptimalperformanceonlywithourgenuineparts

S2:Whatisthetypicalleadtimeforreplacementrotorsor majorshaftcomponents ?
A2 Forcriticalcomponentslikerotors we maintain strategic inventory of key sub assemblies Lead times vary but we target shipment of major components within46weekswithemergencysupportoptionsavailable

S3:Canyourimpactcrusherhandleaclosedcircuitoperationwithareturnfeed( recirculatingload)?
A3 Yes allmodelsaredesignedforthedemandsofclosedcircuitoperations Thesolidrotordesignprovidesthenecessaryinertiaandthehydraulicsystemallowsquickcompensationforchangesinchamberload

S4:Doyouprovideperformanceguarantees ?
A4 Yes weoffercontractualguaranteesforcapacity throughput basedonagreedfeedmaterialanalysis aswellasmaximumwearratesforblowbarsandlinersunderdefinedoperatingconditions

S5:Apakah latihan yang disediakan untuk operator dan kakitangan penyenggaraan kami ?
A5 Weincludecomprehensiveonsiteoperator trainingduringcommissioning coveringnormaloperation adjustmentsafetyprotocolsanddailychecks Indepthmaintenancetrainingfocusedonwearpartreplacementandsystemdiagnosticsisalsoavailable

S6:Iscustomizationavailablefordifferentvoltageorpowersupplyrequirements ?
A6 Absolutely Asanexport specialist weengineereachunittomeetthedestinationcountry’sspecificpowerstandards includingmotors startersandcontrolpanelconfigurations

Q7 Howdoesthecostofownershipcomparetoaconecrusherforsimilarapplications ?
A7 Forlowto mediumabrasivematerials anexportimpactcrusheroffersalowerinitialcapitalinvestment significantlylowerwearcostspertonneproducesamorecubicalproduct butmayhavehigherwearcostsinhighlyabrasiveapplicationscomparedtoacone OurteamcanprovideadetailedTCOanalysisbasedonyourspecificmaterial