Targeting Primary Crushing Bottlenecks: The HighCost of Compromise

Your primary crushing stage sets the tone for your entire downstream process. Inefficiency here cascades, eroding profitability. Are you grappling with the true costs of your current jaw crusher? Consider these operational challenges: Unplanned downtime due to premature wear part failure, custando milhares por hora em perda de produção. Inconsistent feed opening and uneven wear patterns leading to unpredictable product gradation and increased recirculating load. Excessive vibration and structural stress that accelerates fatigue on the chassis and foundation, demanding costly structural repairs. High energy consumption per ton of material processed, directly impacting your operating margin. The constant tradeoff between throughput capacity and final product quality.

Introducing the Certified Jc5000 Jaw Crusher: a heavyduty, singletoggle jaw crusher engineered for maximum throughput and longevity in the most demanding primary crushing applications. Designed for stationary plant installation or robust mobile setups, it processes quarried rock, concreto de demolição, and runofmine ore up to 1200mm in size.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Oversize material is directed into the large feed hopper, with optional grizzly prescreening to bypass fines.
2. Aggressive Crushing Stroke: The highinertia flywheels and an aggressive elliptical crushing motion ensure efficient nipangle breaking at the inlet.
3. Descarga Controlada: The hydraulic toggle adjustment system allows operators to set the closedside setting (CSS) under load for precise product size control.
4. Ejeção de Materiais: Crushed material exits with minimal slabby or flaky product due to the optimized chamber geometry.

Escopo de aplicação: Ideal para produção de agregados de alta tonelagem, hard rock mining primary stations, and largescale construction & demolition recycling plants.
Limitações: Not designed for grinding or ultrafine reduction; maximum feed size and material abrasiveness are bounded by its design specifications.

Recursos principais: Engineering for Operational Superiority

Design de estrutura resistente | Base Técnica: Análise de Elementos Finitos (FEA) distribuição de tensão otimizada | Benefício Operacional: Elimina fissuras por fadiga da estrutura sob carregamento cíclico, ensures alignment integrity | Impacto do ROI: Reduz o risco de falha estrutural catastrófica, extends service life beyond 20+ anos

Sistema de ajuste de alternância hidráulica | Base Técnica: Hydraulic ram replaces traditional mechanical shims | Benefício Operacional: CSS adjustment in minutes versus hours, even while empty | Impacto do ROI: Reduz o tempo de inatividade para alterações de produtos em até 80%, increases plant flexibility

Extinguido & Tempered Jaw Dies | Base Técnica: ISO9001certified alloy steel with specialized heat treatment | Benefício Operacional: Achieves optimal hardnesstoughness balance, resisting abrasive wear and fracture | Impacto do ROI: Aumenta a vida útil em 3050% sobre o aço manganês padrão, reduzindo o custo por tonelada

Spherical Roller Bearing Assembly | Base Técnica: Largediameter bearings with automated lubrication ports | Benefício Operacional: Supports high radial and axial loads, runs cooler under continuous duty | Impacto do ROI: Proven bearing service intervals exceeding 24,000 horas, eliminating a common failure point

PLCIntegrated Protection System | Base Técnica: Continuous monitoring of power draw, temperatura do rolamento, e pressão hidráulica | Benefício Operacional: Prevents tramp metal damage through automated clearing cycles and immediate shutdown on fault detection | Impacto do ROI: Protects core components from irreversible damage, avoiding sixfigure repair bills

Competitive Advantages of the Certified Jc5000 Jaw Crusher

| Métrica de desempenho | Padrão da Indústria (Classe comparável) | Jc5000 Solution Documented Result | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade)| 9294% | Os dados de campo mostram consistência >96% disponibilidade| +34% |
| Use a vida (Rocha Abrasiva)| ~450,000 metric tons per set | Average documented life of 650,000 toneladas métricas| +44% |
| Eficiência Energética| 0.85 kWh/metric ton processed| Verified average of 0.72 kWh/metric ton| +15% redução |
| Tempo de ajuste CSS| 24 horas (mechanical shim) | <30 minutos (sistema hidráulico) |< 85% |
Based on aggregated field performance reports from installed units in granite and basalt quarries.

Especificações Técnicas

Abertura de alimentação: 1500mm x 1200 mm (59" x 47")
Tamanho máximo de alimentação: Up to 1200mm (47") comprimento da borda
Configuração lateral fechada (CSS) Faixa: 150mm 300 mm (6" 12")
Faixa de capacidade: Até 1,750 toneladas métricas por hora (depende do material de feed e CSS)
Requisitos de energia da unidade: Dual drive configuration requiring a total connected power of up to kW/HP.
Peso do britador (Unidade Básica): Approximately XX metric tons.
Construção da Estrutura Principal: Fabricated from heavyduty steel plate with reinforced ribbing; stressrelieved before machining.
Swing Jaw Construction: Forged from a single piece of highstrength steel.
Faixa de temperatura operacional: 20°C a +40°C (4°F a +104°F) with standard lubricants.

Cenários de aplicação

Granite Aggregate Quarrying Challenge:

A largescale quarry faced excessive downtime every two weeks for manual jaw gap adjustment using shims. Product consistency drifted between adjustments.

Solução:

Implementation of a Certified Jc5000 Jaw Crusher as the primary unit.

Resultados:

CSS adjustments reduced from biweekly fourhour tasks to tenminute procedures. Plant managers reported a measurable improvement in gradation consistency (+/5% variação), enabling more efficient downstream screening.

Iron Ore Primary Crushing Challenge:

An iron ore processing plant struggled with premature bearing failures in their primary crusher every ~18 months due to extreme dust ingress and high cyclic loads.

Solução:

Installation of a Certified Jc5000 with its sealed spherical roller bearing labyrinth system connected to an automated grease injection system.

Resultados:

Bearing inspection after two years showed no signs of contamination or spalling. Projected service life now exceeds five years based on condition monitoring data.

Considerações Comerciais

The Certified Jc5000 is positioned as a capital investment focused on total cost of ownership reduction over a minimum tenyear horizon.

Níveis de preços: Base equipment pricing is structured around drive motor configuration options (por exemplo, standard efficiency vs. premium efficiency motors). Export packaging standards also affect base price.
Recursos opcionais & Kits: Key options include an integrated automatic lubrication system for bearings and toggle area; various jaw die profiles for different applications; different liner materials for feed hopper; motor starter package; advanced condition monitoring sensors tied directly into plant SCADA systems.
Pacotes de serviços: Threetiered plans are available:
Bronze – Extended warranty coverage on major components.
Silver – Bronze benefits plus annual inspection by factorycertified technicians.
Gold – Allinclusive coverage including scheduled wear part replacement at prenegotiated rates.
Opções de financiamento: Available through partnered financial institutions include standard equipment leasing structures or project financing tailored for greenfield installations.

Perguntas frequentes

1. Is the Certified Jc5000 compatible with our existing secondary/tertiary crushing circuit?
Sim. Its precisely controllable CSS allows you to tune its output gradation as optimal feed stock for your cone crushers or further processing stages.

2. Qual é o impacto esperado no consumo geral de energia da nossa planta?
Industry testing demonstrates that its higher throughput per kWh can reduce primary crushing energy costs by approximately . This impact is most significant in operations running multiple shifts.

3. How does the hydraulic toggle system handle tramp metal events?
The system includes an automatic release function that allows the moving jaw to yield under extreme pressure from uncrushable material before resetting itself—minimizing downtime without manual intervention.

4.What are typical lead times for delivery?
For standard configuration units built against forecast orders lead time is typically XX months exworks Confirmed orders will receive firm scheduling upon deposit receipt

5.Are there financing options available that separate equipment cost from installation services?
Yes project financing can be structured such that site preparation electrical work installation commissioning services are bundled into a single agreement providing clear budget control

6.Que treinamento é fornecido para nossa equipe de manutenção?
A comprehensive twoday onsite training program covering operation daily checks routine maintenance procedures troubleshooting guides is included with every unit purchase

7.Can we source compatible wear parts locally or must they be OEM?
While dimensional drawings are available allowing local fabrication we strongly recommend genuine OEM parts Their metallurgical specifications directly influence documented performance metrics like throughput wear life