1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão prejudicando a lucratividade da sua pedreira ou mina? Primary crushing bottlenecks can cascade into costly inefficiencies across your entire processing line. Considere estes desafios comuns:
Tempo de inatividade excessivo para manutenção: Frequent liner changes and mechanical adjustments halt production, custando milhares por hora em perda de rendimento.
Paradas não planejadas da Tramp Metal: Britadores desprotegidos que enfrentam material não britável levam a danos catastróficos, resulting in days of repair and parts replacement.
Gradação inconsistente do produto: Fluctuations in feed size or hardness create an uneven discharge, overloading downstream screens and crushers, reducing overall plant efficiency.
Altos custos operacionais: Rising energy consumption per ton and short component lifecycles directly impact your bottom line.

Is your primary crusher a reliable asset or a recurring liability? The solution lies in selecting a jaw crusher engineered not just for power, but for predictable performance and total cost of ownership.

2. VISÃO GERAL DO PRODUTO

O britador de mandíbula JC5000 é um britador de mandíbula de alta capacidade, singletoggle primary crushing station engineered for the most demanding mining, pedreira, e aplicações de reciclagem de construção em grande escala. Its robust design focuses on delivering maximum availability and the lowest cost per ton in its class.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Runofmine or quarryrun material is directed into the large capacity vibrating grizzly feeder (opcional), which bypasses fines to increase effective crushing capacity.
2. Redução Primária: Material enters the deep crushing chamber of the JC5000 Jaw Crusher, where a powerful elliptical motion applies compressive force against a fixed jaw plate.
3. Descarga Controlada: The crushed product exits at the bottom of the chamber, com tamanho determinado pela configuração fechada (CSS), adjustable via a hydraulic toggle system.
4. Plant Integration: The consistent output is conveyed to secondary crushing or screening stages for further processing.

Escopo de aplicação & Limitações:
Escopo: Ideal para hard rock (granito, basalto), minérios abrasivos, and shot rock. Suited for stationary primary crushing stations requiring throughputs from 750 para 1,500 mtph depending on material and settings.
Limitações: Not designed for sticky or clayrich materials without prescreening. Requires a stable concrete foundation and appropriate feed equipment sized to match its inlet capacity.

3. RECURSOS PRINCIPAIS

Alternar Hidráulico & Sistema de ajuste | Base Técnica: Cilindros hidráulicos de dupla ação substituem placas articuladas mecânicas | Benefício Operacional: Permite segurança, rapid CSS adjustment and provides automatic overload protection by releasing to clear blockages | Impacto do ROI: Reduz o tempo de inatividade de ajuste em até 80% em comparação com sistemas de calços manuais; evita grandes danos causados ​​por materiais não trituráveis.

Câmara de britagem simétrica profunda | Base Técnica: Optimized nip angle and long vertical travel at the feed opening | Benefício Operacional: Promotes rockonrock attrition in the upper chamber, reduces wear on lower sections, and enhances throughput | Impacto do ROI: Extends jaw plate life by an estimated 1525%, reducing consumable costs and changeout frequency.

Rolamentos autocompensadores de rolos para serviços pesados | Base Técnica: Largediameter bearings housed in precisionmachined pitman and frame seats | Benefício Operacional: Supports high radial and axial loads from tough crushing cycles with minimal heat generation | Impacto do ROI: Increases bearing service life under shock loading; dados de campo mostram um 30% improvement in mean time between failures versus standard designs.

Base de motor integrada & Protetor de cinto | Base Técnica: Unified steel fabrication that houses crusher motor, vbelt drive, and guards | Benefício Operacional: Eliminates misalignment during installation/transport; provides safer, easier access for maintenance | Impacto do ROI: Cuts installation time by approximately two days; reduces longterm vibrationrelated wear on drive components.

Wedge Lock Jaw Plate Fastening System | Base Técnica: Mechanically locked wedges secure front and rear jaw plates without backing material | Benefício Operacional: Allows fast plate changes with standard tools; creates a secure fit that minimizes plate shifting under load | Impacto do ROI: Reduces liner changeout time by half compared to traditional bolted systems.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Competitor Averages) | Solução de britador de mandíbula JC5000 | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | ~8590% (agendado & paradas não programadas) |> 94% (based on telemetry data) |> 5% aumento nas horas produtivas |
| Eficiência Energética (kW por tonelada) | Linha de base = 100% (varies by application) |> 1215% reduction per ton crushed |> 1215% lower energy cost |
| Vida útil da placa de mandíbula (Rocha Abrasiva) ~500 Mtons| Linha de base = 100% |> Extended wear profile increases life ~20% |> ~20% reduction in consumable cost |
| Overload Recovery Time (Limpeza) ~48 hours| Manual clearing required |> Hydraulic toggle reversal clears most jams in Up to 90% faster recovery |

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1,500mm x 1.200 mm (59" x 47")
Tamanho máximo de alimentação: 1,050milímetros (41")
Recommended Closed Side Setting Range: 150mm 300 mm (6" 12")
Faixa de capacidade: Até 1,500 mtph dependent on material type & CSS
Requisitos de energia da unidade: 200 kW / Até compatível com VSD
Peso total (Apenas triturador): Aproximadamente 86 toneladas
Principais especificações de materiais: Estrutura de aço fabricada de alta resistência; Manganese steel jaw plates; Eixo excêntrico de liga de aço forjado.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C (4°F a +113°F). Kits de vedação contra poeira disponíveis para ambientes áridos.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Desafio: Uma operação existente necessária para aumentar o rendimento do circuito primário em 40% without expanding its physical footprint or secondary circuit. The incumbent crusher could not achieve higher capacity without unacceptable vibration and premature wear.
Solução: Installation of one JC5000 Jaw Crusher as the new primary unit with an optimized feeder setup.
Resultados: O rendimento aumentou em 42%. The consistent product gradation reduced cycling in the secondary cone crushers. Plant managers reported a 22% decrease in specific energy consumption at the primary stage within the first year.

Atualização da planta de processamento de minério de ferro

Desafio: Unplanned downtime due to tramp metal incidents was causing an average of three major stoppages annually at this site’s primary crush station.
Solution Replacement with a JC5000 equipped with its integrated hydraulic overload protection system.
Results In two years of operation zero catastrophic events have occurred from tramp metal Hydraulic clearing activated four times preventing an estimated 14 days of downtime saving over $350k in lost production

7 CONSIDERAÇÕES COMERCIAIS

The JC5000 Jaw Crusher is offered as part of several commercial packages:

Níveis de preços:
Tier A Base Unit includes crusher motor base belt guards basic tooling
Tier B Plant Ready includes integrated motorized feeder skid structure walkways ladders
Tier C Turnkey includes full electrical control package dust suppression starter package

Recursos opcionais:
Heavy duty grizzly feeder with fines bypass conveyor
Automatic grease lubrication system
Remote monitoring telemetry package for CSS amp draw bearing temps

Pacotes de serviços:
Standard Warranty months parts labor
Extended Service Plan years including scheduled inspections wear part discounts
Full Maintenance Contract covers all parts labor inspections fixed annual fee

Financing Options available through partner institutions include capital lease operating lease or leaseto own structures typically ranging from months

8 Perguntas frequentes

What are my foundation requirements for the JC5000?
Detailed civil drawings are provided A reinforced concrete foundation designed for dynamic loads exceeding tons is required We provide full load data specifications

Can I use existing feeders conveyors with this crusher?
Compatibility depends on their rated capacity Our engineers can review your existing layout The JC inlet requires proper feed distribution which may necessitate feeder modifications

How does hydraulic overload protection work compared shear pins?
The hydraulic toggle uses pressurized nitrogen accumulators When an uncrushable object is encountered pressure increases releasing cylinders allow movement then automatically reset No components need replacement unlike broken shear pins minimizing restart time

What is your expected delivery lead time?
For standard configuration units lead time is typically weeks from order confirmation Long lead items like custom motors may affect this Expedited manufacturing options are sometimes available

Você oferece garantias de desempenho?
Yes we offer guaranteed minimum throughput capacities based on agreed feed material testing These are contractually defined prior to purchase