1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? Para gerentes de fábrica e especialistas em compras, selecting the right primary crushing equipment is a critical capital decision with longterm consequences. Os desafios comuns incluem:

Tempo de inatividade excessivo para manutenção: Frequent liner changes and component failures can halt your entire production line for days, custando milhares por hora em perda de produção.
Unpredictable Wear Part Costs: Inconsistent material quality leads to rapid abrasion of crusher components, creating volatile and uncontrollable operational expenses.
Saída inconsistente & Formato do produto: Poorly graded final product with excessive flaky content can cause issues in downstream processes like screening and secondary crushing, reduzindo a eficiência geral da planta.
Alto consumo de energia: Projetos de britadores mais antigos ou ineficientes consomem energia desproporcional por tonelada de material processado, impactando diretamente seus resultados financeiros.
Rigidez à variação da alimentação: Fluctuations in feed size or hardness often cause blockages or require manual intervention, slowing throughput and increasing labor costs.

A questão central é: como você consegue confiabilidade, hightonnage reduction of hard rock and ores while maintaining control over your total cost of ownership? The answer lies in selecting a stone crusher machine engineered not just for peak performance, but for sustained profitability under realworld conditions.

2. VISÃO GERAL DO PRODUTO

This product line encompasses a series of highperformance Britadores de mandíbulas designed as robust primary crushers for the most demanding mining, pedreira, and aggregate production applications. Engineered for continuous operation with abrasive materials like granite, basalto, e minério de ferro.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Grande matéria-prima (até 1500 mm) é carregado no alimentador vibratório do urso pardo, which bypasses fines to optimize crushing chamber loading.
2. Redução Primária: Material enters the deep crushing chamber where a powerful eccentric shaft drives a moving jaw plate against a fixed jaw plate, applying compressive force to break the rock.
3. Ajuste de configuração de descarga: The crushed material exits at the bottom at a size determined by the closedside setting (CSS), which is hydraulically adjustable for quick product grading changes.
4. Downstream Transfer: The crushed output is conveyed to the next stage of processing (secondary crushing or screening).

Escopo de aplicação & Limitações:
Ideal para: Britagem primária de material duro, materiais abrasivos; stationary and semimobile quarry plants; highcapacity mining operations.
Limitações: Não é adequado para pegajoso, materiais plásticos; requires a stable foundation and significant installation planning; maximum reduction ratios are typically lower than specialized tertiary crushers.

3. RECURSOS PRINCIPAIS

Design de mandíbula modular | Base Técnica: Aparafusados, nonwelded frame construction | Benefício Operacional: Enables transportation to remote sites and reduces foundation requirements | Impacto do ROI: Lowers logistical and civil works costs by up to 15% during installation.

Alternar Hidráulico & Sistema de ajuste | Base Técnica: Substitui placas articuladas mecânicas tradicionais por cilindros hidráulicos | Benefício Operacional: Enables remote adjustment of CSS for product control and provides automatic overload protection by releasing tramp metal | Impacto do ROI: Reduz em mais de tempo de inatividade para alterações de configuração 70% and prevents major damage from uncrushables.

Geometria otimizada da câmara de britagem | Base Técnica: Computermodeled kinematics and a deep symmetrical chamber | Benefício Operacional: Promotes interparticle crushing for better shaped aggregate, increases capacity per unit of power draw | Impacto do ROI: Improves final product yield within specification by an average of 8%, enhancing downstream efficiency.

Rolamento Pesado & Conjunto de eixo forjado | Base Técnica: Oversized spherical roller bearings on a highstrength forged eccentric shaft | Benefício Operacional: Sustains peak loads from hard rock feeds with minimal heat generation and vibration | Impacto do ROI: Prolonga a vida útil do rolamento em mais 40%, reducing spare part inventory costs.

Base de motor integrada & Proteção de transmissão por correia | Base Técnica: Unified base frame for crusher motor/vbelt drive with full safety guarding | Benefício Operacional: Simplifies alignment during installation/commissioning; ensures operator safety compliance (OSHA/CE) from day one | Impacto do ROI: Cuts commissioning time by approximately 30 hours while mitigating regulatory risk.

Metalurgia de peças de desgaste & Projeto | Base Técnica: Manganese steel jaw plates with optimized tooth profiles based on application analysis (feed type) | Benefício Operacional: Increases wear life through workhardening properties; maintains consistent throughput longer between changes | Impacto do ROI: Field data shows a documented 2035% improvement in liner life compared to standard OEM offerings.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Vantagem documentada da nossa solução de britador de mandíbula |
| : | : | : |
| Disponibilidade (Tempo de atividade) | ~92% (incluindo. manutenção programada) |>96% due to reduced unplanned stops |
| Tonnage per kWh Consumed| Varia de acordo com o tipo de rocha |>510% melhoria na eficiência energética |
| Tempo médio entre falhas (Key Bearings)| ~1215k operating hours |>20k operating hours |
| Horas de trabalho para substituição de peças de desgaste| 1624 hours for jaw plate change|<12 horas com ferramentas de assistência hidráulica |
| Índice de formato do produto (% Cúbico)| Tipicamente 82%, improving asphalt/concrete mix quality |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: 150 1,200 toneladas por hora (depende do material de alimentação e da configuração do lado fechado).
Tamanhos de abertura de alimentação: Ranging from 750mm x 500mm up to 1500mm x 1200mm.
Requisitos de energia: Motor principal do britador de 75 kW até 250 kW; total installed power including feeder/conveyor drives varies by plant configuration.
Especificações de materiais: Estrutura de aço soldada de alta resistência (Q345B); JAW Plates Mn18Cr2 / Mn22Cr2 optional; Eccentric Shaft 42CrMo forged steel.
Dimensões Físicas (Aprox., largest model): Length ~6m x Width ~3.5m x Height ~4m (excluindo alimentador).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Os sistemas de vedação contra poeira são padrão; noise emissions comply with <85 dB(UM) at one meter under load.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Challenge A quarry operator needed to increase primary throughput by 40% without expanding their existing plant footprint or foundation due to space constraints.
Solution Implementation of our modular jaw crusher with an optimized deepchamber design allowed higher capacity within similar external dimensions. The hydraulic adjustment system facilitated quick changes between railway ballast and concrete aggregate products.
Results Achieved a sustained throughput increase of 42%. Product shape improvement reduced recirculating load in the secondary cone circuit by an estimated 15%, lowering overall plant wear.

Atualização da planta de processamento de minério de ferro

Challenge An aging primary crusher suffered from chronic bearing failures every 810 months due to extreme shock loads from direct dump feeding, causing costly line stoppages.
Solution Replacement with our heavyduty jaw crusher featuring the oversized bearing assembly and hydraulic overload protection system was specified.
Results After two years of operation, no bearingrelated issues have been reported. Plant managers report an estimated saving of over $50k annually in avoided downtime and emergency parts procurement.

7. CONSIDERAÇÕES COMERCIAIS

Our stone crusher machines are offered in clear pricing tiers based on model size and core configuration:
Nível Padrão: Base machine with standard manganese jaws, mechanical Vbelt drive guards, kit de ferramentas básicas.
Nível de desempenho: Includes hydraulic adjustment system upgraded bearing monitors wear part fastchange kits applicationspecific jaw plate profiles (+812% investimento).
Premium Service Package Available separately includes extended warranty on major components planned maintenance inspections annual health check reports priority parts dispatch guaranteed response times

Financing options include traditional capital equipment leasing through our partners as well as projectbased financing solutions tailored for largescale greenfield developments

8. Perguntas frequentes

Q Qual é o prazo de entrega após a confirmação do pedido?
A For standard models lead time is typically between weeks depending on final specifications Custom configurations may require additional engineering time

Q Are your machines compatible with existing conveyor systems or feeders from other manufacturers?
A Yes Our engineering team can provide interface drawings Our discharge heights belt widths are designed to common industry standards ensuring compatibility

P Como sua empresa oferece suporte ao comissionamento da instalação?
A We provide detailed foundation drawings comprehensive installation manuals Onsite supervision technical support during commissioning is available as part of an optional service package

Q What is your policy regarding wear spare parts availability?
A We maintain strategic stockpiles of critical wear parts Our commitment ensures availability within hours/days depending on location supported by guaranteed supply agreements

Q Can you provide sitespecific performance projections before purchase?
A Absolutely Based on your feed material samples target product gradation we will conduct crushability analysis provide detailed capacity power consumption wear life estimates

Q What training do you provide for operational maintenance staff?
A We offer standardized operational training videos manuals Onsite training sessions covering safe operation routine maintenance troubleshooting procedures are included with supervised commissioning