H1: Private Label Impact Crushers: Engineered for HighVolume Aggregate Profitability

Subheader: Specify, brand, and deploy robust reduction machinery designed to lower your cost per ton in demanding quarry and recycling operations.

1. Operational Challenges in Aggregate Reduction

Are rising operational costs and unpredictable downtime eroding your margins? For plant managers and commercial buyers, the primary crushing stage presents critical bottlenecks that directly impact profitability. Key challenges include:

Excessive Wear Part Costs: Frequent replacement of hammers, liners, and blow bars due to inconsistent feed material or suboptimal chamber design.
Unscheduled Downtime for Maintenance: Extended, complex procedures for rotor inspection or wear part changeouts halt your entire production line.
Inconsistent Product Gradation: Fluctuations in output particle size distribution, leading to rejected loads and recrushing that wastes energy and capacity.
High Energy Consumption per Ton: Inefficient crushing action and system design that inflate your most significant variable operating cost.
Rigidity in Application Scope: Crushers that cannot adapt to varying feed materials (e.g., switching between limestone and recycled concrete) without significant reconfiguration or performance loss.

How do you select a primary or secondary impact crusher that addresses these specific cost centers with engineering precision, not just promises?

2. Product Overview: Private Label Impact Crushers

Our private label impact crushers are heavyduty, horizontal shaft impactors (HSI) engineered for highvolume reduction of aggregates, concrete, and asphalt. We provide the fully engineered platform; you apply your brand and specifications for a seamless fit within your equipment portfolio.

Operational Workflow:
1. Feed Intake: Material is directed into a largecapacity feed hopper with integrated grizzly or prescreen to bypass fines.
2. Acceleration & Impact: Feed material is propelled by the highinertia rotor into the adjustable primary curtain(s), initiating fracture.
3. Controlled Reduction: Material rebounds into the adjustable secondary curtain(s) or grinding path for further size reduction.
4. Product Ejection: Correctly sized material exits through the adjustable bottom grate, ensuring final product specification.

Application Scope: Primary or secondary crushing of low to mediumabrasive materials: limestone, dolomite, recycled concrete & asphalt (RCA/RAP), slag. Ideal for stationary plants or large portable tracked setups.

Limitations: Not recommended as a primary crusher for highly abrasive materials (e.g., granite, trap rock) where compressive crushers offer superior wear life. Optimal performance requires consistent feed size control upstream.

3. Core Features & Engineering Benefits

Hydraulic Adjustment System | Technical Basis: Centralized hydraulic cylinders for curtain positioning | Operational Benefit: Adjust product gradation or clear blockages in minutes from a single station without manual shim removal | ROI Impact: Reduces adjustment downtime by up to 85%, increasing annual machine utilization

Monobloc Rotor Design | Technical Basis: Solid steel rotor disc forged as a single unit with welded wear plates | Operational Benefit: Eliminates disc separation risks under high stress, maintains precise balance for sustained throughput | ROI Impact: Extends major rotor service intervals by 3050%, protecting against catastrophic failure

MultiFunctional Access Doors | Technical Basis: Large rear service door with integrated lifting points | Operational Benefit: Provides full access to the crushing chamber for safe liner changes and thorough inspection | ROI Impact: Cuts scheduled maintenance time by half, improving labor efficiency

ClassLeading Feed Opening & Chamber Design | Technical Basis: Deep chamber geometry optimized via CFD analysis for materialonmaterial breakage | Operational Benefit: Accommodates larger feed sizes and promotes stoneonstone fracture, reducing wear on metallurgy | ROI Impact: Lowers cost per ton by distributing wear across the chamber environment

PLCBased Condition Monitoring Ports | Technical Basis: Integrated sensor ports for vibration & temperature monitoring connected to plant control systems | Operational Benefit: Enables predictive maintenance scheduling based on actual rotor bearing condition, not just hours run | ROI Impact Prevents unplanned stoppages and allows parts procurement in advance

4. Competitive Advantages at a Glance

| Performance Metric | Industry Standard Benchmark | Our Private Label Impact Crusher Solution | Documented Advantage |
| : | : | : | : |
| Wear Part ChangeOut Time (Primary Curtain) | 46 hours (manual shim) | 80% improvement |
| Rotor Rebuild Interval (Limestone) | ~600k tons MTBR | ~900k tons MTBR| ~50% improvement |
| Power Efficiency (kW per ton output) Varies by material| Baseline = 100%| Field data shows 8892% of baseline consumption| 812% improvement |
| Product Gradation Consistency (± % passing key sieve)| ± 7% variance| ± 3% variance via hydraulic adjustment lock| > 55% improvement |

Mean Time Between Rebuilds – based on internal field data tracking.

5. Technical Specifications Overview

Capacity Range: Models available from 300 TPH to over 800 TPH nominal throughput (dependent on feed material and product size).
Power Requirements: Driven by 400 800 kW electric motors; compatible with Tier 4 Final / Stage V diesel power packs for mobile configurations.
Rotor Specifications: Solid steel monobloc design; diameters from ~1.2m to ~1.6m; widths from ~1.3m to ~2m.
Key Material Specifications: Primary curtains & blow bars available in multiple alloys (e.g., highchrome martensitic steel, ceramic composite). Mainframe constructed from quenched & tempered steel plate.
Physical Dimensions (Example Model): Feed opening up to ~1600mm x 2000mm. Transport weight approximately 35 55 metric tons depending on configuration.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust sealing compliant with standard industry emission control expectations.

6. Application Scenarios & Documented Outcomes

Limestone Quarry Primary Crushing | Challenge A major aggregate producer faced excessive downtime from blow bar changes every week and poor shape factor on their existing impactor.| Solution Implementation of our private label HSI crusher with hydraulic curtain adjustment and specialized blow bar metallurgy.| Results Blow bar life extended to three weeks. Hydraulic adjustments allowed operators to finetune for optimal shape factor daily. This resulted in a documented 22% reduction in cost per ton of finished aggregate.

Recycled Concrete Aggregate (RCA) Production Facility Challenge An urban recycling plant struggled with unpredictable contamination (rebar, wood) causing stall events and damage requiring fullday shutdowns.| Solution A configured private label impact crusher with an overloadprotected drive system and programmable automatic reversal function.| Results The system now detects jams and autoreverses within seconds, clearing most blockages without operator intervention. Stallrelated downtime was reduced by an estimated 90%, achieving consistent weekly production targets.

7. Commercial Considerations

Our private label program is structured for scalability and partnership.

Pricing Tiers: Based on model size/capacity range:
Tier I (600 TPH): Extraheavyduty configuration
Pricing is FOB manufacturing facility with volumebased discounts.

Optional Features & Upgrades:
Advanced automation packages (full PLC control integration)
Specialized wear part metallurgy packages
3rd party component branding options
360° service platform kits

Service Packages Available PostPurchase:

1. Basic Warranty Package
2.Planned Maintenance Agreement
3.FullService Contract including wear parts monitoring

Frequently Asked Questions

Q1 Are these crushers compatible with our existing plant control system?
Yes They are equipped with standard industrial PLC interfaces Modbus TCP/IP Ethernet/IP which allow them integrate into most supervisory SCADA systems providing operational data alarm reporting

Q2 What is typical lead time from specification order delivery?
Lead times vary based model complexity current order volume Standard configurations can ship within weeks while fully customized units require planning Typical range weeks months Detailed schedule provided upon project initiation

Q3 How does private labeling work what level customization possible?
We supply complete painted but unbranded crusher You apply your own logos decals color scheme Further customization possible feed openings drive arrangements specific component brands align your supply chain

Q4 What documented impact can expect energy consumption compared older technology?
Field performance audits indicate modern rotor design optimized chamber geometry can reduce specific energy consumption kWh per ton processed compared decade old designs Improvements largely depend achieving consistent optimal feed size distribution

Q5 What are payment terms financing options available?
Standard terms deposit upon order confirmation balance before shipment We work third party equipment financing partners offer lease purchase loan structures tailored capital expenditure plans typical terms years available qualified buyers