1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e a disponibilidade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Para gerentes de fábrica e empreiteiros de engenharia, o britador giratório é um ativo crítico onde as falhas têm consequências exponenciais. Os desafios comuns incluem:
Tempo de inatividade não programado: Bearing failures or mainshaft issues can halt entire processing lines for days, costing hundreds of thousands in lost production.
Altos custos de manutenção: Freqüente, laborintensive liner changes and component wear directly impact maintenance budgets and manpower allocation.
Taxa de transferência inconsistente: Poor feed distribution or worn crushing surfaces lead to product gradation fluctuations, downstream bottlenecks, and reduced overall plant efficiency.
Ineficiência Energética: Older or poorly optimized designs consume excessive power per ton of processed material, a fixed cost that directly affects operating margins.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The answer lies in a purposeengineered gyratory crusher from a dedicated private label manufacturer focused on R&Ddriven performance.

2. VISÃO GERAL DO PRODUTO

This product is a highcapacity primary gyratory crusher, engineered for private label partners who require robust, applicationspecific solutions for largescale mining and aggregate operations. Its design focuses on delivering maximum availability and optimal reduction ratios for hard, abrasive ores and rock.

Fluxo de Trabalho Operacional:
1. Aceitação de feed: Oversize material from haul trucks or loaders is directed into the steepsided feed hopper.
2. Ação Esmagadora: The hydraulically adjusted mainshaft assembly gyrates within the concave liners, applying compressive force to reduce material size.
3. Descarga: Crushed product exits through the discharge opening at the bottom of the crushing chamber, with size controlled by the hydraulic setting adjustment system.
4. Manuseio de Materiais: The product is conveyed to downstream secondary crushing or screening circuits.

Escopo de aplicação & Limitações:
Escopo: Ideal para alta tonelagem (2,000+ TPH) primary crushing applications in metal ore mines (cobre, ferro, ouro), large quarries producing aggregate, and major construction projects requiring onsite primary reduction.
Limitações: Não é adequado para operações de baixa tonelagem (<500 TPH), recycling applications with high tramp metal content without extensive protection systems, or portable/mobile plant installations due to size and weight.

3. RECURSOS PRINCIPAIS

Perfil côncavo patenteado | Base Técnica: Optimized crushing chamber geometry based on discrete element modeling (DEM) | Benefício Operacional: Delivers a consistent chokefed crushing action for uniform wear and stable product gradation | Impacto do ROI: Extends liner life by an average of 1520%, reducing liner cost per ton and changeout frequency

Integrated Smart Bearing System | Base Técnica: Multisensor monitoring of bearing temperature, vibração, and lubrication pressure | Benefício Operacional: Provides early warning diagnostics to prevent catastrophic bearing failure | Impacto do ROI: Eliminates unplanned downtime events related to bearing issues, protecting millions in potential production losses

Hydraulic Setting & Proteção contra sobrecarga | Base Técnica: Dualfunction hydraulic cylinder for precise CSS adjustment and automatic relief under uncrushable material | Benefício Operacional: Allows operators to adjust product size remotely and protects the crusher from mechanical damage | Impacto do ROI: Reduces setting time by 70% compared to manual systems and prevents costly repairs from tramp steel events

TopService Design Philosophy | Base Técnica: All routine service tasks (mudanças de revestimento, spider arm refurbishment) accessible from above | Benefício Operacional: Eliminates the need for personnel to work beneath suspended components or dismantle the crusher structure | Impacto do ROI: Reduz o tempo de inatividade programada para manutenção em até 50%, enhancing plant availability

Acionamento direto & Torque Limiter System | Base Técnica: Lowspeed synchronous motor coupled via an air clutch with torque limiter | Benefício Operacional: Provides smooth startup under load capability and protects drive train from shock loads | Impacto do ROI: Reduces electrical stress during startup by 60% versus VFDonly solutions, lowering peak demand charges

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | This Gyratory Crusher Solution | Vantagem documentada |
| : | : | : | : |
| Disponibilidade Mecânica (Alvo) | 92 94% | >96% (Contractual Target) | +24 pontos percentuais |
| Vida útil do forro (Minério Abrasivo) | ~6 meses (Varia) | 78 Meses (Average Field Data)| +1520% Melhoria |
| Consumo Específico de Energia (kWh/t) ~0,8 1.2 kWh/t ~0.7 0.9 kWh/t ~1015% Improvement |
| Tempo de ajuste CSS <4 Horas 75% Mais rápido |
| Custo total de propriedade (5Projeção do ano)| Baseline Model Averages +1218% Menor TCO |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 2,000 acabar 10,000 toneladas métricas por hora (tph), depending on model size and feed material.
Potência do motor: Unidades padrão de 450 kW até 1 PM+; engineered to client specifications.
Abertura de alimentação: Tamanhos de abertura de 1,300 mm para 1,800 mm available.
Especificações de materiais:
Quadro Principal & Head Center: Highstrength cast steel alloy.
Côncavo & Mantle Liners: Ligas de aço manganês; optional premium alloys for specific abrasion/impact conditions available.
Eixo Principal: Forged alloy steel with precision machining.
Dimensões Físicas & Peso: Pegada significativa; exact dimensions provided per model. Approximate installed weights range from 350 toneladas para mais 800 toneladas.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C com sistemas de lubrificação apropriados; padrão de vedação contra poeira.

6. CENÁRIOS DE APLICAÇÃO

Expansão da Mina de Cobre

Challenge A Tier1 copper operation needed to increase primary circuit throughput by 25% without expanding their truck fleet or dump pocket footprint. Their existing crusher was a bottleneck with frequent linerrelated downtime.

Solution Implementation of our largestcapacity gyratory crusher model featuring the patented concave profile for higher reduction ratio in a single pass.

A produtividade dos resultados aumentou em 28%. Liner life improved from an average of approximately five months to sixandahalf months under identical ore conditions. Annual production targets were met three weeks ahead of schedule following commissioning.

Granite Quarry Primary Circuit Upgrade

Challenge A major aggregate producer faced volatile energy costs and high maintenance expenses on their aging primary crusher. Product consistency was also an issue affecting their premium product lines.

Solution A midrange gyratory crusher was selected with a focus on energy efficiency via direct drive optimization and superior chamber geometry.

Results Specific energy consumption decreased by an average of approximately twelve percent yearoveryear despite increased operating hours.The consistent gradation reduced recirculating load in secondary circuits by nearly eighteen percent.The quarry reported meeting tighter specification bands more reliably for key customer contracts.

7. CONSIDERAÇÕES COMERCIAIS

Our private label manufacturing model provides flexible commercial pathways tailored for OEMs and largescale endusers:

Níveis de preços: Structured around core model size (abertura de alimentação), drive power rating,and level of standard automation.Control system integration is offered as either basic local control or full PLC/SCADA interface packages.

Recursos opcionais & Atualizações: Key options include advanced predictive maintenance sensor suites,kits de anéis de supressão de poeira,material level monitoring systems,and proprietary wearresistant alloy packages for liners.

Pacotes de serviços: Available service agreements range from basic technical documentation support through comprehensive multiyear performance contracts covering planned maintenance,inspections,and guaranteed parts availability with defined response times.

Opções de financiamento: We work with established financial partners ableto structure leasing arrangements,tailored payment plans aligned with project milestones,and other financing solutions upon request.This facilitates capital budget planningfor our clients' projects.

8.Perguntas frequentes

P:What levelof engineering supportis provided duringthe integrationof thisgyratorycrusherintoan existingplantlayout?
A OurR&Dandapplicationengineeringteamsworkdirectlywithyourprojectengineersto reviewfoundationdesignsfeedanddischargearrangementsandinterfacingwithexistingconveyorsystemsWe providecomprehensivelayoutdrawingsforcesandloaddatato ensureproperintegration

P:Canyourcrushersbeconfiguredtooperatewithautomationsystemssuppliedbyothervendors?
A YesThecorecrushercontrolsystemisdesignedwithstandardindustrialcommunicationprotocols(egOPCUAProfibusEthernet/IP)allowingforseamlessdataintegrationintoplantwideprocesscontrolandmonitoringsystems

P:Whatisthetypicalleadtimefromordertocommissioningforastandardmodel?
A Leadtimesvarybymodelsizeandcustomizationbutgenerallyrangefrom12to18monthsforcompletecrushersupplyincludingengineeringmanufacturingfactorytestinganddeliverySchedulesareconfirmeduponprojectkickoff

P:Aretheredocumentedcasesofretrofittingyourcrushingchambertechnologyintoexistinggyratorycrushersfromothermanufacturers?
A WhileourprimaryfocusisnewunitswehaveexecutedseveralsuccessfulmodernizationprojectsforcompatiblelegacycrushersTheseinvolvereplacingkeywearcomponentsandsometimeshydraulicsystemstodeliverperformanceimprovementsAcasestudyreviewcanbe provideduponrequest

P:Whatdefinesthe"TotalCostofOwnership"advantageinyourcomparisons?
A OurTCOanalysisovera5yearperiodaccountsforinitialcapitalcostenergyconsumptionprojectedwearpartslifeandreplacementcostsscheduledmaintenancelaborhoursandexpectedavailabilitylossesFielddatafromsimilarenvironmentsformsthebasisfortheseprojections

P:Doyouoffertestcrushingofcustomermaterialsamplespriorto purchase?
A YesWeoperateapilotscalecrushingfacilityandcanperformcomprehensivematerialtestworkincludingabrasivenessandcompressionstrengthanalysisto validatecapacitymodelingandliner liferecommendationsThisdataisincludedinourtechnicalproposal

P:Whatarethestandardwarrantytermsforthemainmechanicalcomponents?
A Themainstructuralcomponents(mainframeheadcenter)mainshaftassemblyandbearingscarryastandardwarrantyof24monthsfromcommissioningor26monthsfromshipmentwhicheveroccurfirstsubjecttocorrectinstallationoperationasperourmanuals