1. PEMBUKAAN PAINPOINT DRIVEN

Are escalating operational costs and unpredictable downtime eroding your quarry's profitability? Untuk pengurus loji dan kontraktor kejuruteraan, ballast production presents distinct challenges that directly impact the bottom line. Titik kesakitan biasa termasuk:
Penjanaan Denda Berlebihan: Hingga 1520% of processed material can fall below spec, turning potential revenue into waste stockpiles.
Penggunaan Bahagian Haus yang Tinggi: The abrasive nature of trap rock, granit, and basalt leads to premature liner and hammer failure, menyebabkan kerap, costly maintenance stops.
Inconsistent Product Cubicity: Poor particle shape in the final product reduces track bed stability and can lead to product rejection.
Ketidakcekapan Tenaga: Older crushing stages consume disproportionate power for the usable tonnage produced, inflating operational expenses.
Kapasiti Tidak Fleksibel: Fixed plants struggle to adapt to fluctuating demand, creating bottlenecks or underutilization.

Is your current setup equipped to maximize yield from every ton of feed while controlling maintenance costs and energy consumption? The right primary crushing equipment is the foundational answer.

2. GAMBARAN KESELURUHAN PRODUK: ODM QUARRY PRIMARY JAW CRUSHER FOR BALLAST PRODUCTION

This product line focuses on heavyduty primary jaw crushers engineered specifically for highvolume ballast production from hard, abrasive feed materials. As an ODM (Pengeluar Reka Bentuk Asal), we provide customized crushing solutions built to your precise operational parameters and site constraints.

Aliran Kerja Operasi:
1. Pengurangan utama: ROM (RunofMine) batu kuari, typically up to 800mm in size, is fed into the crusher's robust vibrating grizzly feeder (VGFF VGF) section.
2. PraSkrining & Menghancurkan: VGF menghilangkan denda semula jadi dan memintas bahan subsaiz, hanya menghalakan batu besar ke dalam ruang penghancuran. The deep,symmetrical jaw chamber performs the initial compressive break.
3. Product Shaping: The kinematics of the jaw plate motion are optimized to promote interparticle crushing, enhancing particle cubicity on the first pass.
4. Pelepasan & Pengangkutan: Crushed material is discharged at a consistent CSS (Tetapan sampingan tertutup) onto the primary conveyor for transport to secondary screening and crushing stages.

Skop Permohonan & Batasan:
Sesuai Untuk: Primary crushing of hard, batu igneus yang melelas (granit, basalt) and dense limestone for railway ballast and construction aggregates.
Batasan: Tidak sesuai untuk melekit, claybound materials without prescreening/scalping. Feed size is constrained by crusher model inlet dimensions.

3. CIRI TERAS

HeavyDuty Rolled Steel Frame | Asas Teknikal: Singlepiece, stressrelieved fabrication | Faedah Operasi: Menghilangkan rekahan keletihan bingkai di bawah beban kitaran; provides stable platform for precision bearing alignment | Kesan ROI: Extended structural life exceeding 20+ years reduces capital replacement risk.

Geometri Bilik Dioptimumkan & Kinematik | Asas Teknikal: ST/DT (Steep/Deeper Toggle) cavity design with aggressive nip angle | Faedah Operasi: Meningkatkan daya pengeluaran sehingga 10% at same power draw; promotes better particle shape for downstream processing | Kesan ROI: Higher yield of inspec product per operating hour directly increases revenue.

Hydroset CSS Adjustment System | Asas Teknikal: Hydraulic cylinders support the toggle seat for safe setting adjustment | Faedah Operasi: Closedside setting changes can be made in minutes under load or during clearing strokes, without manual shims | Kesan ROI: Mengurangkan masa henti untuk perubahan saiz produk lebih 80%, enhancing plant flexibility.

LongLasting Manganese Jaws with Clamp Systems | Asas Teknikal: Isovitric supergrade manganese steel with reversible design; mechanical clamp system for fast replacement | Faedah Operasi: Jaw life increased by 2530%; changeout time reduced from days to a single shift | Kesan ROI: Lowers costperton for wear parts and significantly increases plant availability.

Integrated PreScreening Grizzly Feeder | Asas Teknikal: Boltin grizzly sections with adjustable slope and gap settings | Faedah Operasi: Removes up to 20% of fines prior to crushing chamber, reducing unnecessary wear and improving chamber efficiency | Kesan ROI: Directly lowers wear part consumption and power cost per ton of crushed material.

Sistem Gris Automatik Berpusat | Asas Teknikal: Programmable lubrication unit serving all key bearing points | Faedah Operasi: Ensures optimal bearing lubrication intervals; prevents both under and overgreasing failures | Kesan ROI: Extends critical bearing service life by an average of 35%, preventing catastrophic downtime.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Purata) | ODM Quarry Jaw Crusher Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Adanya (Masa aktif) | ~8590% (dijadualkan & berhenti tidak berjadual) |> 94% (based on field monitoring data) |> +5% Penambahbaikan |
| Kos Pakai setiap Tan (Batu Abrasive) $0.12 $0.18/ton| 25% Pengurangan |
| Penggunaan Kuasa Khusus| Berbeza secara meluas; older units > 0.8 kWh/ton @ CSS 150mm| 19% Pengurangan |
| Penjanaan Denda (<22mm)| ~1822% of total feed| 30% Pengurangan |
| Indeks Flakiness Produk (Sasaran 30% after primary stage| Consistently Improved Shape |

5. SPESIFIKASI TEKNIKAL

Kapasiti Julat Model: 400 1,800 tan sejam (Tph), depending on feed material and closedside setting.
Pembukaan suapan: Daripada 1,000mm x 650mm hingga 1,500mm x 1,200mm.
Keperluan kuasa: Drive motor from 90 kW sehingga 300 kw; total installed power including feeder hydraulics specified per model.
Spesifikasi Bahan: Rangka dikimpal berkekuatan tinggi (Keluli S355JR); Isovitric manganese crusher jaws; forged alloy steel eccentric shaft with largediameter spherical roller bearings.
Dimensi Fizikal & Berat: Approximate weights from 35 tan ke 120 tan; detailed layout drawings provided for foundation planning.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; dust sealing compliant with ISO standard levels; noise emissions designed below 105 db(A) di stesen operator.

6. SENARIO APLIKASI

Hard Rock Quarry Supplying National Rail Project

Cabaran: A granite quarry needed to supply over 2 million tons of Type I ballast within a strict timeline but faced excessive wear costs and fines generation (>22%) from their existing primary crusher.
Penyelesaian: Implementation of a customconfigured ODM heavyduty jaw crusher with an integrated aggressive grizzly feeder profile optimized for their specific granite blend.
Keputusan: Fines generation reduced to below spec at <14%. Wear part lifecycle extended by approximately28%. The project was completed ahead of schedule due to sustained throughput rates averaging12% above target.

Aggregate Producer Expanding into Rail Ballast Market

Cabaran: An established aggregate producer lacked a primary stage capable of producing the consistent cubicity required by rail authorities without excessive secondary recrushing.
Penyelesaian: Installation of an ODM jaw crusher with a specially engineered chamber profile focused on firstpass shape optimization.
Keputusan: Final product Flakiness Index achieved directly after primary crushing met rail specification (<25%), reducing load on secondary cone crushers by approximately15%. This allowed reallocation of secondary capacityto other product lines.

7. PERTIMBANGAN KOMERSIL

Our ODM approach provides structured commercial flexibility:

Peringkat Harga Peralatan: Based on model size/capacity range:
Peringkat I (1200 Tph): Fully customized solutions with advanced monitoring packages included.

Ciri Pilihan & Pakej:
Advanced PLC automation package with loadregulation logic
Wear part monitoring sensors
Penyepaduan sistem penindasan habuk
Modular skidbase design for faster installation

Pakej Perkhidmatan:
Basic Warranty Package
Comprehensive Service Agreement including scheduled inspectionsand parts discounts
Pemasangan Turnkey & Sokongan Pentauliahan

Pilihan Pembiayaan:
We work with international export credit agenciesand equipment financing partners t o offer leasetoown arrangements , mediumterm loans , or tailored rentalpurchase agreements t o align w ith your project cash flow .

8.Soalan Lazim

Q:What level o f customization i s possible w ith your ODM jaw crushers?
A.We can modify several parameters including feeder dimensions ,grizzly bar configuration ,discharge conveyor interface points ,and motor mounting positions t o ensure compatibility w ith your existing plant layoutand feed system .

Q.How does this equipment improve our overall plant efficiency beyond justtheprimary stage?
A.B y deliveringa more consistent ,cubicalproductatthefirststage,yoursecondaryand tertiarycrushers operate more efficiently .This reduces circulating loadsand improves finalproductyieldwhile loweringtotalplantpowerconsumption .

Q:What i sthetypical delivery lead timeforacustomized unit?
A.Forstandardmodels withinourTierI&IIrange ,lead timesaretypically1622weeksfromorderconfirmation .FullycustomizedTier IIIsolutionsrequire detailed engineeringand mayextendto28weeks .Proactive planningi srecommended .

Q.Arewearparts interchangeablewithothercrusherbrands?
A.No .Ourwearpartsaredesigned specificallyforourchambergeometryandkinematics t oensureoptimalperformanceand longevity .We providecomplete technicaldrawingsforinventory planning .

Q.What kindo f foundationi srequired ?
A.We providecomprehensivefoundationdrawingswitheachorderincludingallstaticand dynamicloaddata .Foundationsaretypicallyreinforcedconcrete ;our engineerscanreviewyoursitespecificplansuponrequest .

Q.Doyouoffertrainingforouroperatorsandmaintenancestaff ?
A.Y es.O nsiteoperationalandsafetytrainingduringcommissioningi sincludedwith everysale .Additionalmaintenancetrainingmodulesareavailableaspartofourservicepackages .

Q.Whatarethekeyfactorsin determiningthecorrectmodelsizeforourapplication ?
A.Capacityselectionisbasedonfourprimaryfactors :yourmaximumfeedsizematerialhardnessorBWI( BondWorkIndex ),desiredproductsize( CSS ),andrequiredhourlytonnage .Ourtechnicalteamwillanalyze yoursamplesandspecificationst orecommendtheoptimalmodel