Private Label JC5000 Jaw Crusher Catalog

Your Crushing Operations Are Underperforming—Here’s the Cost

Every hour of unplanned downtime in your primary crushing circuit costs between $5,000 dan $15,000 dalam pengeluaran yang hilang, depending on your feed tonnage and material value. If your current jaw crusher is delivering less than 85% masa beroperasi, you are leaving significant revenue on the table. High wear rates on jaw plates force premature replacements every 3–4 months, adding $12,000–$18,000 annually in consumable costs alone. Inconsistent product gradation creates recirculation loads that reduce overall plant efficiency by 12–18%. Feed blockages from oversized material or sticky ores cause manual intervention, exposing your operators to safety risks and halting production for 30–90 minutes per incident.

Are you absorbing these costs because you believe all jaw crushers perform the same? What if a single equipment upgrade could reduce your cost per ton by 15% while extending wear life by 40%?

Gambaran Keseluruhan Produk: The Private Label JC5000 Jaw Crusher

The Private Label JC5000 is a heavyduty primary jaw crusher engineered for continuous operation in hard rock mining, Pengeluaran agregat, and construction demolition recycling. It processes feed material from 500mm to 1,200mm, reducing it to a consistent 100–250mm product in a single pass.

Aliran Kerja Operasi:
1. Pemuatan Suapan: Material enters through the 1,200mm x 900mm feed opening via excavator, wheel loader, or conveyor
2. Primary Compression: The fixed jaw and moving jaw create a Vshaped crushing chamber; the eccentric shaft drives the pitman to generate compressive forces exceeding 350 MPa
3. Patah Bahan: Rock is crushed against the fixed jaw plate through multiple compression cycles as it descends through the chamber
4. Discharge Regulation: The closed side setting (CSS) adjusts from 75mm to 200mm via hydraulic wedges, controlling product size
5. Material Exit: Crushed material discharges onto a belt conveyor or into a surge bin for secondary processing

Skop Permohonan: Batu keras (granit, basalt, kuarzit), batu mediumhard (batu kapur, dolomit), recycled concrete and asphalt, mining ores (Tembaga, emas, besi)

Batasan: Not suitable for clayrich materials exceeding 15% kandungan kelembapan; requires 6–8 weeks lead time for custom jaw plate profiles; maximum feed size limited to 80% lebar bukaan suapan

Ciri Teras

Geometri Ruang Penghancuran Dioptimumkan | Asas Teknikal: Analisis unsur terhingga (FEA) optimized toggle plate angle and chamber profile | Faedah Operasi: Reduces recirculating load by 22% compared to straight chamber designs | Kesan ROI: Lowers energy consumption by 8–12 kWh per 100 tan diproses

Sistem Pelarasan CSS Hidraulik | Asas Teknikal: Twin hydraulic cylinders with position sensors adjust the closed side setting in under 3 minit | Faedah Operasi: Menghapuskan pelarasan shim manual, reducing changeover time by 85% | Kesan ROI: Recovers 40–60 minutes of production time per setting change

HighStrength Manganese Jaw Plates | Asas Teknikal: 18% manganese alloy with chromium carbide overlay on wear zones | Faedah Operasi: Achieves 14,000–18,000 tons of wear life in granite applications | Kesan ROI: Reduces annual consumable costs by $4,500–$7,200 per crusher

Advanced Flywheel Design | Asas Teknikal: Dual flywheels with 8,500 kg·m² moment of inertia | Faedah Operasi: Mengekalkan daya penghancuran yang konsisten semasa kitaran beban puncak, reducing motor current spikes by 30% | Kesan ROI: Extends motor and Vbelt life by 18–24 months

Sistem Pelinciran Automatik | Asas Teknikal: Programmable grease injection to all bearing points at 15minute intervals | Faedah Operasi: Menghapuskan pelinciran manual, mengurangkan buruh penyelenggaraan dengan 3 jam setiap minggu | Kesan ROI: Prevents bearing failures that cost $8,000–$12,000 per replacement event

Reversible Jaw Plate Design | Asas Teknikal: Symmetrical plate geometry allows 180degree rotation | Faedah Operasi: Doubles usable wear life before replacement | Kesan ROI: Saves $2,800–$4,500 per set of jaw plates

Bantuan Besi Tramp Bersepadu | Asas Teknikal: Hydraulic relief cylinder with 350bar pressure threshold | Faedah Operasi: Melepasi objek yang tidak boleh dihancurkan (bit gerudi, gigi baldi) without structural damage | Kesan ROI: Avoids $15,000–$25,000 in frame repair costs per incident

Kelebihan Kompetitif

| Metrik Prestasi | Piawaian Industri (200–300 HP Jaw Crusher) | Penyelesaian Label Peribadi JC5000 | Kelebihan (% Penambahbaikan) |
|||||
| Throughput (tan/jam) | 250–350 tph | 320–420 tph | 20–28% higher |
| Masa aktif (purata tahunan) | 82–88% | 93–97% | 10–15% improvement |
| Kos setiap tan (memakai bahagian) | $0.18–$0.25 | $0.12–$0.16 | 33–36% reduction |
| Masa pelarasan CSS | 15–25 minit | 2–3 minutes | 85–88% faster |
| Kehidupan plat rahang (granit) | 9,000–12,000 tons | 14,000–18,000 tons | 40–55% longer |
| Motor power consumption | 0.8–1.2 kWh/ton | 0.6–0.9 kWh/ton | 20–25% lower |
| Feed opening utilization | 65–75% | 80–90% | 15–20% improvement |

Spesifikasi Teknikal

| Parameter | Spesifikasi |
|||
| Pembukaan suapan | 1,200 mm x 900 mm (48" x 36") |
| Saiz suapan maksimum | 950 mm (37") |
| Julat CSS | 75–200 mm (3"–8") |
| Kapasiti throughput | 320–420 tph (based on CSS and material density) |
| Kuasa motor | 250–300 kW (335–400 HP) |
| Kelajuan Motor | 1,500 Rpm (50 Hz) / 1,800 Rpm (60 Hz) |
| Kelajuan aci eksentrik | 220–260 RPM |
| Flywheel Weight (setiap satu) | 4,250 kg |
| Jumlah Berat (penghancur sahaja) | 38,500 kg |
| Bahan Rangka Utama | DALAM 10025 Keluli struktur S355JR, 40ketebalan mm |
| Bahan Plat Rahang | 18% Mn, 2% Cr, 1.2% C (ASTM A128 Gred C) |
| Jenis Galas | Galas penggelek sfera, SKF 23244 CC/W33 |
| Lubrication Capacity | 8 liters grease reservoir |
| Julat Suhu Operasi | 20°C hingga +50°C (4°F hingga +122°F) |
| Dimensi (L x W x H) | 3,800 mm x 2,400 mm x 3,100 mm |
| Konfigurasi Penghantaran | 2 x 20foot containers (crusher and motor separately) |

Senario Aplikasi

Kuari Batu Keras, Norway | Cabaran: Pemprosesan 800,000 tan/tahun granit dengan 18% silica content caused jaw plate wearout every 2,800 jam, memerlukan 32 jam masa henti bagi setiap penggantian | Penyelesaian: Private Label JC5000 with 18% manganese jaw plates and reversible design | Keputusan: Jangka hayat plat rahang dilanjutkan ke 4,100 jam (46% penambahbaikan); annual downtime reduced from 128 jam ke 72 jam; cost per ton decreased from $0.22 ke $0.14

Kitar Semula Perobohan Pembinaan, Jerman | Cabaran: Processing mixed demolition waste with rebar and concrete required frequent tramp iron events, causing structural damage to previous crusher every 6 bulan | Penyelesaian: JC5000 with integrated hydraulic tramp iron relief and automatic reset | Keputusan: Zero structural damage over 18 bulan beroperasi; tramp iron passage time reduced from 45 minit ke 4 minit; plant uptime increased from 79% ke 94%

Copper Mine, Chile | Cabaran: Primary crushing at 4,200 meters altitude with 35°C temperature swings caused lubrication failures in standard crushers | Penyelesaian: JC5000 with highaltitude lubrication package and thermal expansion compensation | Keputusan: Bearing failures eliminated over 24month period; throughput maintained at 380 tph despite altitude; maintenance costs reduced by $18,000 setiap tahun

Pertimbangan Komersial

Peringkat Harga Peralatan:

• Pakej Standard ($285,000–$315,000): Crusher assembly, 250 motor kW, Pemacu Vbelt, standard manganese jaw plates, kit alat asas
• Pakej Dipertingkatkan ($345,000–$385,000): Includes hydraulic CSS system, pelinciran automatik, wireless remote control, spare jaw plate set
• Pakej Premium ($425,000–$475,000): Full automation package with PLC control, Pemantauan getaran, oil analysis sensors, 3year wear parts warranty

Ciri Pilihan:

• Custom jaw plate profiles for specific feed materials: $4,500–$8,000 per set
• Highaltitude modification kit (above 3,000m): $12,500
• Sistem penindasan habuk (water spray nozzles): $6,800
• Motor soft starter or VFD: $9,500–$18,000
• Pakej telemetri pemantauan jarak jauh: $7,200

Pakej Perkhidmatan:

• Kontrak penyelenggaraan tahunan: $18,000/tahun (termasuk 2 pemeriksaan, sokongan teknikal keutamaan)
• Fullservice agreement: $42,000/tahun (includes all scheduled maintenance, wear parts at cost, 48hour response guarantee)
• Training package: $6,500 (3day onsite operator and maintenance training for up to 8 kakitangan)

Pilihan Pembiayaan:

• Pajakan peralatan: 36–60 bulan terma dengan $1 belian, starting at $6,800/month
• Bayaran tertunda: 90penangguhan pembayaran hari dengan 0% interest for qualified buyers
• Program Tradein: Hingga $45,000 credit for qualifying used jaw crushers (200 HP or larger)

Soalan Lazim

1. What is the lead time for a Private Label JC5000?
Standard production lead time is 8–10 weeks from order confirmation. Penghantaran dipercepatkan (6 minggu) tersedia dengan a 5% surcaj. Custom jaw plate configurations add 2–3 weeks.

2. Can the JC5000 process recycled concrete with rebar?
ya. The hydraulic tramp iron relief system passes rebar up to 25mm diameter without damage. For larger rebar concentrations, we recommend a prescreening grizzly to remove oversized steel.

3. What is the expected annual maintenance cost?
berdasarkan 2,000 operating hours per year in hard rock applications, annual maintenance costs average $22,000–$28,000, including jaw plate replacement (one set), bearing lubrication, and minor repairs.

4. Does the JC5000 require a concrete foundation?
ya. A reinforced concrete foundation with minimum dimensions of 5m x 4m x 1.5m is required, with anchor bolts embedded to our provided template. Foundation design support is included with the purchase.

5. Apakah perlindungan waranti yang disediakan?
Perlindungan jaminan standard 24 bulan atau 6,000 waktu operasi, yang mana dahulu. Coverage includes structural frame, Aci eksentrik, dan galas. Pakai bahagian (Plat rahang, togol pinggan) dikecualikan. Pilihan jaminan lanjutan tersedia.

6. Can the JC5000 be integrated with existing plant control systems?
ya. The PLCbased control system supports Modbus RTU, Profibus, and Ethernet/IP protocols. Integration documentation and technical support are provided at no additional cost.

7. Apakah tahap bunyi semasa operasi?
Pada 1 jarak meter, the JC5000 operates at 85–92 dB(A) di bawah beban penuh. We recommend hearing protection for operators within 15 meter. Optional acoustic enclosures reduce noise to 78 db(A) di 1 meter.