1. PEMBUKAAN PAINPOINT DRIVEN

Managing a limestone quarry or processing plant presents distinct operational challenges that directly impact your bottom line. Adakah anda sering bertengkar, unplanned downtime from equipment not engineered for abrasive materials? Are maintenance costs for wear parts consuming your operational budget? Perhaps inconsistent feed size to your primary crusher is creating bottlenecks, or dust suppression is failing to meet increasingly stringent environmental standards. Each hour of lost production and every premature component replacement erodes profitability. The right primary crushing solution must address these specific pain points: durability against abrasive silica, reliability under continuous hightonnage loads, and integration with your downstream processing flow. How do you select equipment that turns these cost centers into competitive advantages?

2. GAMBARAN KESELURUHAN PRODUK

The solution is a heavyduty, singletoggle jaw crusher engineered specifically for primary crushing in limestone mining applications. This robust piece of mineral processing machinery is designed to accept large feed material directly from the quarry face and reduce it to a consistent, manageable size for secondary processing.

Aliran Kerja Operasi:
1. Suapan: Runofquarry (ROQ) batu kapur, often with high silica content and variablesized boulders up to the crusher’s specified maximum feed size, dibuang ke dalam penyuap grizzly yang bergetar (VGFF VGF).
2. PraSkrining & Menghancurkan: VGF mengeluarkan denda dan memintas bahan subsaiz, hanya menghalakan batu besar ke dalam ruang penghancuran. The aggressive elliptical motion of the singletoggle jaw exerts massive compressive force against the fixed jaw plate.
3. Pelepasan: Bahan hancur keluar melalui bukaan nyahcas boleh laras, ensuring a controlled product size that optimizes throughput for the next stage in your plant.

Skop Permohonan & Batasan:
Skop: Ideal for hightonnage primary crushing of blasted limestone, dolomit, and other mediumabrasive aggregates. Suited for both stationary plants and semimobile setups.
Batasan: Not designed for very hard, igneous rock (mis., granit, basalt) as a primary crusher without significant tradeoffs in wear life and efficiency. Memerlukan kandang, engineered foundation and appropriate upstream feeding equipment.

3. CIRI TERAS

Ruang Penghancuran Dalam & Kinematik Agresif | Asas Teknikal: Optimized nip angle and long vertical jaw plate travel | Faedah Operasi: Creates high reduction ratios in a single pass, minimizing recirculation load and handling larger block sizes effectively | Kesan ROI: Increases effective throughput by 812% compared to standard chambers, reducing energy per ton crushed.

Quenched & Tempered Alloy Steel Jaw Plates | Asas Teknikal: Metallurgical process enhancing surface hardness (450500 BHN) with a tough core | Faedah Operasi: Exceptional resistance to abrasion from limestone’s silica content; plates are reversible for extended service life | Kesan ROI: Didokumenkan 3040% longer wear life over standard manganese steel, directly lowering costperton for wear parts.

Galas Penggelek Sfera Tugas Berat & Pitman Design | Asas Teknikal: Oversized bearings with high load ratings and a stressrelieved forged steel pitman | Faedah Operasi: Sustains continuous operation under shock loads from uncrushable material; enables full horsepower draw without risk of premature bearing failure | Kesan ROI: Eliminates costly bearingrelated downtime; data lapangan menunjukkan a 99.2% operational availability rate in 24/7 limestone operations.

Pangkalan Motor Bersepadu & Pemacu VBelt | Asas Teknikal: Unified frame design housing motor and drive guards | Faedah Operasi: Eliminates misalignment issues; simplifies tensioning and maintenance; reduces installation footprint and time | Kesan ROI: Cuts installation labor by approximately 25 hours and ensures optimal power transmission efficiency.

Titik Greasing Berpusat & Accessible Design | Asas Teknikal: Labyrinth seals fed from a singlepoint greaser and strategically placed service platforms | Faedah Operasi: Membolehkan selamat, rapid routine maintenance (tension checks, pelinciran) di bawah 30 minit tanpa alat khusus | Kesan ROI: Increases planned maintenance compliance by simplifying tasks, preventing neglect that leads to major failures.

Sistem Pelarasan Togol Hidraulik (Pilihan) | Asas Teknikal: Hydraulic cylinder replaces traditional toggle plates/tension rods | Faedah Operasi: Allows remote adjustment of crusher discharge setting for product size control and provides automated clearing of chamber blockages in minutes | Kesan ROI: Reduces downtime for product changeovers or clearing events by over 85%, memaksimumkan masa operasi loji.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Generic Jaw Crusher) | Our LimestoneOptimized Jaw Crusher Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Wear Life of Jaw Plates| Standard 14% Keluli mangan | Q&T Alloy Steel with Reversible Design| +35% (Dipanjangkan Umur) |
| Ketersediaan Operasi| ~95% (Dijadualkan & Masa Henti Tidak Berjadual)| >99% (Proven in Field Data)| +4% Masa aktif |
| Tan sejam setiap kW| Garis dasar 100% Efficiency Rating| Kinematik yang dioptimumkan & Drive Efficiency| +9% Kecekapan tenaga |
| Masa Purata Antara Baik pulih Utama| 2430 Months under High Abrasion| 3642 Months Documented Service Life| +40% Service Interval |

5. SPESIFIKASI TEKNIKAL

Penamaan model: JC1500HDLS
Pembukaan suapan: 59” x 47” (1500mm x 1200mm)
Saiz suapan maksimum: 47” (1200mm) panjang tepi
Tetapan sampingan tertutup (CSS) Julat: 6” – 12” (150mm – 300mm)
Julat Kapasiti (@ CSS): 750 – 1,450 STPH (680 – 1,315 MTPH), Bergantung pada ciri -ciri material.
Keperluan Kuasa Pandu: 300 Hp / 250 motor elektrik kW.
Jumlah Berat (Penghancur Sahaja): ~125,000 paun (~56,700 kg)
Spesifikasi Bahan Utama: Fabricated main frame with reinforced ribs; Forged eccentric shaft; Q&T alloy steel jaw plates; Highgrade bronze toggle seats.
Dimensi Fizikal (LxWxH): Lebih kurang. 12’ x ‘ x ‘ (Note specific dimensions vary).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C (4°F hingga +113°F). Dust seals rated for typical quarry conditions.

6. SENARIO APLIKASI

LargeScale Aggregate Producer & Cement Plant Feedstock Supplier

Challenge A major operator faced excessive wear part costs and biweekly downtime for jaw plate changes on their primary crusher processing highsilica limestone.
Solution Implementation of the JC1500HDLS with Quenched & Tempered alloy steel plates and centralized greasing.
Results Wear part life extended from weeks to weeks ( hari). Annual maintenance downtime reduced by hours (%), translating to an additional , tons of crushed material produced annually without increasing operating hours.

MidSized Limestone Quarry Expanding Output

Challenge A growing operation needed higher primary crushing throughput but was constrained by existing foundation space and feared lengthy installation shutdowns.
Solution Deployment of our jaw crusher with its integrated motor base design as part of a semimodular skid system.
Results Installation was completed in days versus the projected days for conventional assembly. The optimized kinematics allowed throughput to meet new plant design capacity of , TPH without requiring a larger footprint or more powerful motor.

7. PERTIMBANGAN KOMERSIL

Our pricing structure is based on providing clear value tiers aligned with operational needs:

Peringkat Peralatan Asas: Includes the core crusher with standard jaw plates, manual adjustment system, and basic drive guards.
Peringkat Prestasi: Adds the Hydraulic Toggle Adjustment System (HTAS), Quenched & Tempered jaw plates as standard,and upgraded dust sealing packages.
Premium Plant Integration Tier: Includes Performance Tier features plus customengineered feed hopper/VGF interface modulesand prewired lubrication systemsfor turnkey installation support.

Ciri pilihan termasuk sistem pelinciran automatik,pemula motor,and various liner profilesfor specific product shaping.Service packages range from basic commissioning supportto comprehensive multiyear Planned Maintenance Agreements(PMAs)that include scheduled inspections,diskaun pakai bahagian,and priority technical support.Financing options through our partners include capital leasesoperating leasesand leasetoown programsto preserve capital expenditure budgets.

8. Soalan Lazim

Q1 Is this crusher compatible with my existing secondary cone crusher circuit?
A1 Yes.The discharge product gradation is engineered to be optimal feedfor most secondary cone crushers.We provide detailed product curve analysis based on your target CSS settings to ensure compatibilitywith your specific downstream equipment

S2 Apakah kesan yang dijangkakan pada tahap bunyi keseluruhan tumbuhan saya?
A2 Industry testing demonstrates that our heavyduty designwith precisionmachined components operates at lower vibration levelswhich contributes to reduced noise emissionscompared to older or less rigid designs.Specific dB(A) levels at given distances are available upon request

Q3 How does the optional Hydraulic Toggle System affect routine maintenance?
A3 It significantly simplifies it.The system removes manual shims allowing CSS adjustment via control panelin minutesIt also incorporates tramp iron reliefreducing riskof damage during uncrushable eventsand can be usedto assistin plate changes

Q4 What are typical lead timesfor deliveryand what site preparationis required?
A4 Lead times vary basedon configurationbut standard modelsare typically availablewithin monthsDetailed foundation drawingswith all load pointswill be provided wellin advance requiringa levelengineered concrete foundationof specified strength

Q5 Are spare parts readily availableand whatis your support structure?
A5 We maintaina global networkof distribution centersstocking critical wear partsand componentsOur support includesremote diagnosticscapabilityand field service engineersspecializedin mineral processing equipment

Q6 Can you providea detailed costpertonanalysisfor my specific operation?
A6 AbsolutelyOur application engineering teamwill request key data includingyour annual tonnageabrasion indexpower costsand currentwear part consumptionto modela precise operating cost comparisonversusyour current solution

Q7 What warrantyis offeredon themain structureand components?
A7 The main frame eccentric shaftand bearingsare coveredbya year warrantyagainst defectsin materialsand workmanshipWear partslike jaw plates carrya performance warrantybasedon minimum guaranteed tonnageunder defined operating conditions