1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? For plant managers and engineering contractors, the primary gyratory crusher is a critical asset where failures have exponential consequences. Common challenges include:
Unscheduled Downtime: Bearing failures or mantle wear issues can halt upstream mining and downstream processing for days, costing tens of thousands per hour in lost production.
High Maintenance Labor & Parts Costs: Frequent, complex liner changes and manual adjustments consume hundreds of manhours annually and drive up spare parts inventory costs.
Inconsistent Product Size: Worn or poorly adjusted crushers produce outofspec feed for secondary circuits, reducing overall plant throughput and recovery rates.
Energy Inefficiency: Older or poorly optimized designs draw excessive power per ton of material processed, directly impacting operational expenditure.

Is your operation constrained by these recurring issues? The solution lies not in incremental upgrades, but in a fundamentally reengineered approach to primary crushing.

2. PRODUCT OVERVIEW

The Private Label Gyratory Crusher is a heavyduty, primary compression crusher engineered for the first stage of reducing runofmine ore to a manageable size for conveying and further processing. Its operational workflow is based on a reliable gyrating mantle within a concave crushing chamber:

1. Feed Intake: Large runofmine material is directed into the top of the crusher’s deep chamber via dump trucks or feeders.
2. Compressive Crushing: The eccentrically gyrating mantle continuously compresses material against the stationary concaves, applying progressive rockonrock and rockoniron reduction.
3. Discharge Setting Control: The crushed product exits at the bottom opening; its size is precisely controlled by adjusting the vertical position of the mantle via the hydroset system.

Application Scope: Ideal for hightonnage (5,000+ TPH) mining operations processing hard rock ores (iron, copper, gold) and aggregates. It is the preferred choice for slabby feed material and sticky clays that would challenge jaw crushers.

Limitations: Not suitable for lowtonnage operations (<1,000 TPH) due to high capital cost. Requires significant foundational support and a controlled feed system to operate at peak efficiency.

3. CORE FEATURES

Patented ASRi+ Automation System | Technical Basis: Realtime condition monitoring & adaptive crushing logic | Operational Benefit: Automatically maintains optimal crusher load and closedside setting (CSS) for varying feed conditions | ROI Impact: Field data shows consistent 510% throughput increase and up to 15% reduction in liner wear costs

Segmented Concave & Mantle Design | Technical Basis: Modular wear part segments with advanced alloy chemistry | Operational Benefit: Enables partial liner replacement during scheduled maintenance, drastically reducing changeout time from days to hours | ROI Impact: Reduces liner change downtime by up to 60%, lowering labor costs and production loss

Integrated Lube & Hydraulic System | Technical Basis: Redundant filtration circuits with temperature control | Operational Benefit: Ensures continuous clean oil flow to critical bearings and the hydraulic setting adjustment (Hydroset), preventing thermal shutdowns | ROI Impact: Industry testing demonstrates a >40% reduction in bearingrelated failures over a 5year period

Spiderless Top Shell Design | Technical Basis: Eliminates traditional spider arms through reinforced rim design | Operational Benefit: Removes potential bottlenecks for large feed material; simplifies access for maintenance | ROI Impact: Increases effective feed opening utilization by ~20%, reducing bridging risk

BottomShell Eccentric Bushing Design | Technical Basis: Largediameter, precisionmachined bushing with forced lubrication | Operational Benefit: Provides exceptional stability under shock loads from uncrushable material; extends major component life | ROI Impact: Projects show major overhaul intervals extended by 23 years compared to legacy designs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Baseline | Private Label Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Operational Uptime) | 92 94% | 96 98% sustained availability target| +4% improvement |
| Specific Energy Consumption (kWh/t) Varies by material hardness| Baseline = 100%| Optimized chamber geometry & drive efficiency reduces consumption| Up to 7% reduction |
| Liner ChangeOut Time (Major)| ~72 hours| Segmented design & tooling reduces time to 58% faster |
| Mean Time Between Failure (MTBF) Major Components| ~24 months typical for bearings/bushings under heavy load| Enhanced lubrication & metallurgy increases MTBF target| Target of +50% improvement |
| Throughput Consistency (Tonnage Variance)| +/ 10% with manual CSS adjustment| ASRi+ automation maintains CSS within +/ 3mm variance|< +/ 5% variance |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable models from 2,000 to over 15,000 metric tons per hour (tph).
Motor Power: Dependent on model size; standard range from 450 kW to over 1,200 kW. Designed for direct online starting with softstart options.
Feed Opening: Gape sizes from 1,000 mm to 1,600 mm.
Material Specifications:
Main Frame & Top Shell: Highstrength fabricated steel (ASTM A36 equivalent or higher).
Concaves & Mantle Core: Manganese steel alloys (1114% Mn), with optional premium alloys for highly abrasive ores.
Eccentric & Bushings: Forged steel with Babbitt metal lining.
Physical Dimensions & Weight: Varies significantly by model; largest models exceed 12m in height with installed weights over 500 tonnes. Foundation loading data provided per project.
Environmental Operating Range: Designed for ambient temperatures from 30°C to +50°C. Dust sealing systems are rated for IP65 protection.

6. APPLICATION SCENARIOS

Copper Mine Expansion, South America

Challenge: An expanding openpit operation needed to increase primary crushing capacity by 25%. Their existing crushers suffered from frequent downtime due to thermal events in the lube system and slow mantle changes causing production bottlenecks.
Solution: Installation of one new Private Label Gyratory Crusher featuring the integrated lube system with cooling redundancy and segmented mantle design.
Results: Achieved sustained throughput of 8,500 tph. Liner change time reduced from 68 to 26 hours. Annual availability recorded at 97.3%, exceeding plant targets.

LargeScale Granite Quarry Operation

Challenge: Highly variable feed size from blasting led to constant operator intervention on CSS adjustment, causing inconsistent product gradation for secondary cone crushers and increased recirculating load.
Solution: Retrofit of an existing gyratory crusher station with the Private Label ASRi+ Automation System package.
Results: Product size distribution variability improved by over 60%. Throughput increased by an average of 8% without increasing power draw. Operators were redeployed to other supervisory tasks.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Offered across three valueengineered tiers:
Standard Duty: For consistent, less abrasive feeds (e.g., limestone). Most costeffective CAPEX.
Heavy Duty: Standard specification for most hard rock mining applications; includes core features like segmented liners.
Extreme Duty: For highly abrasive ores or severe operating conditions; includes premium metallurgy packages and enhanced monitoring systems as standard.

Optional Features / Packages: ASRi+ Automation System upgrade kit; Dust Suppression Sealing Package; Advanced Predictive Monitoring Sensors; Customized Tooling Kits for maintenance.

Service Packages: Multitiered annual service agreements are available covering planned maintenance inspections, priority parts dispatch (+24/7 critical coverage), remote diagnostics support, and lifecycle optimization reporting.

Financing Options: Flexible capital equipment financing can be structured through partners including operating leases tailored to project cash flow models or traditional term loans.

8. FAQ

Q1: Is this gyratory crusher compatible with my existing plant control system?
A1 Yes. The control interface is designed using open communication protocols (Modbus TCP/IP). It can be integrated as a standalone unit or fully into your central SCADA/DCS system.

Q2 What is the expected impact on my operational staffing?
A2 The automation features reduce the need for constant manual adjustment but do not eliminate skilled operator oversight. Your team will transition towards monitoring performance analytics and planning predictive maintenance rather than reactive adjustments.

Q3 How does your total cost of ownership compare over ten years?
A3 While initial capital investment may be comparable or slightly higher than some alternatives our field data indicates significantly lower operating costs leading typically yielding a lower total cost ownership after years twothree Key savings areas are energy consumption liner wear parts labor

Q4 What are lead times delivery installation support?
A4 Lead times vary model complexity Current standard lead time manufacture shipping ranges months months Projectspecific schedules are provided upon application review We provide comprehensive installation supervision commissioning services ensure correct setup performance validation

Q5 Can you provide wear part guarantees based specific ore characteristics?
A5 Yes We offer conditional performance guarantees our liners based detailed analysis your ore sample Our metallurgists will specify alloy recommend profile maximize service life tonnage crushed specific application