1. PEMBUKAAN PAINPOINT DRIVEN

Adakah peningkatan kos operasi dan ketersediaan yang tidak dapat diramalkan menghakis keuntungan litar penghancur utama anda? Untuk pengurus loji dan kontraktor kejuruteraan, penghancur gyratory adalah aset kritikal di mana kegagalan mempunyai akibat eksponen. Cabaran biasa termasuk:
Masa Henti Tidak Berjadual: Bearing failures or mainshaft issues can halt entire processing lines for days, costing hundreds of thousands in lost production.
Kos Penyelenggaraan Tinggi: Kerap, 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.
Ketidakcekapan Tenaga: 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. GAMBARAN KESELURUHAN PRODUK

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.

Aliran Kerja Operasi:
1. Penerimaan Suapan: Oversize material from haul trucks or loaders is directed into the steepsided feed hopper.
2. Tindakan Menghancurkan: The hydraulically adjusted mainshaft assembly gyrates within the concave liners, applying compressive force to reduce material size.
3. Pelepasan: Crushed product exits through the discharge opening at the bottom of the crushing chamber, with size controlled by the hydraulic setting adjustment system.
4. Pengendalian bahan: The product is conveyed to downstream secondary crushing or screening circuits.

Skop Permohonan & Batasan:
Skop: Sesuai untuk hightonnage (2,000+ Tph) primary crushing applications in metal ore mines (Tembaga, besi, emas), large quarries producing aggregate, and major construction projects requiring onsite primary reduction.
Batasan: Tidak sesuai untuk operasi lowtonnage (<500 Tph), recycling applications with high tramp metal content without extensive protection systems, or portable/mobile plant installations due to size and weight.

3. CIRI TERAS

Profil Cekung yang Dipatenkan | Asas Teknikal: Optimized crushing chamber geometry based on discrete element modeling (DEM) | Faedah Operasi: Delivers a consistent chokefed crushing action for uniform wear and stable product gradation | Kesan ROI: Extends liner life by an average of 1520%, reducing liner cost per ton and changeout frequency

Integrated Smart Bearing System | Asas Teknikal: Multisensor monitoring of bearing temperature, getaran, and lubrication pressure | Faedah Operasi: Provides early warning diagnostics to prevent catastrophic bearing failure | Kesan ROI: Eliminates unplanned downtime events related to bearing issues, protecting millions in potential production losses

Hydraulic Setting & Perlindungan beban | Asas Teknikal: Dualfunction hydraulic cylinder for precise CSS adjustment and automatic relief under uncrushable material | Faedah Operasi: Allows operators to adjust product size remotely and protects the crusher from mechanical damage | Kesan ROI: Reduces setting time by 70% compared to manual systems and prevents costly repairs from tramp steel events

Falsafah Reka Bentuk Perkhidmatan Atas | Asas Teknikal: All routine service tasks (Perubahan pelapik, spider arm refurbishment) accessible from above | Faedah Operasi: Eliminates the need for personnel to work beneath suspended components or dismantle the crusher structure | Kesan ROI: Mengurangkan masa henti penyelenggaraan berjadual sehingga 50%, enhancing plant availability

Pemanduan Terus & Torque Limiter System | Asas Teknikal: Lowspeed synchronous motor coupled via an air clutch with torque limiter | Faedah Operasi: Provides smooth startup under load capability and protects drive train from shock loads | Kesan ROI: Reduces electrical stress during startup by 60% versus VFDonly solutions, lowering peak demand charges

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | This Gyratory Crusher Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Ketersediaan Mekanikal (Sasaran) | 92 94% | >96% (Contractual Target) | +24 mata peratusan |
| Kehidupan Pelapik (Bijih Pelelas) | ~6 Bulan (Varies) | 78 berbulan-bulan (Average Field Data)| +1520% Penambahbaikan |
| Penggunaan Tenaga Khusus (kWj/t) ~0.8 1.2 kWh/t ~0.7 0.9 kWh/t ~1015% Improvement |
| Masa Pelarasan CSS <4 Jam 75% Lebih pantas |
| Jumlah Kos Pemilikan (5Unjuran Tahun)| Baseline Model Averages +1218% TCO yang lebih rendah |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 2,000 ke atas 10,000 Ton metrik sejam (tph), depending on model size and feed material.
Kuasa motor: Pemacu standard dari 450 kW sehingga 1 MW+; engineered to client specifications.
Pembukaan suapan: Saiz gape dari 1,300 mm ke 1,800 mm available.
Spesifikasi Bahan:
Bingkai utama & Head Center: Highstrength cast steel alloy.
Cekung & Mantle Liners: Aloi keluli mangan; optional premium alloys for specific abrasion/impact conditions available.
Aci utama: Forged alloy steel with precision machining.
Dimensi Fizikal & Berat: Significant footprint; exact dimensions provided per model. Approximate installed weights range from 350 tan hingga lebih 800 tan.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C dengan sistem pelinciran yang sesuai; standard pengedap habuk.

6. SENARIO APLIKASI

Pengembangan Lombong Tembaga

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.

Keputusan Throughput meningkat sebanyak 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. PERTIMBANGAN KOMERSIL

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

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

Ciri Pilihan & Naik taraf: Key options include advanced predictive maintenance sensor suites,kit cincin penindasan habuk,material level monitoring systems,and proprietary wearresistant alloy packages for liners.

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

Pilihan Pembiayaan: 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.Soalan Lazim

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