1. ABERTURA ACIONADA POR PAINPOINT

Are you managing primary crushing operations where inconsistent feed, materiais abrasivos, and unplanned downtime are eroding your profitability? Considere os custos tangíveis: a single hour of crusher downtime can halt an entire processing line, custando milhares em perda de rendimento. Premature wear on jaw dies from silica abrasion leads to frequent, costly changeouts and excessive maintenance labor. Inefficient crushing with poor nip angles results in higher energy consumption per ton and unwanted fines generation. Are you facing the challenge of achieving required capacity without a footprint that disrupts your plant layout? These operational hurdles directly impact your bottom line through increased cost per ton, missed production targets, and strained maintenance budgets. A questão central para os gerentes de fábrica é esta: how do you secure a primary crusher that delivers consistent performance, withstands severe service, and provides predictable operating costs?

2. VISÃO GERAL DO PRODUTO

O britador de mandíbula JC5000 é um britador de mandíbula de alta capacidade, singletoggle jaw crusher engineered for stationary primary crushing applications in mining, heavyduty construction, and largescale aggregate production. Its design focuses on reducing runofmine material or large quarry stone to a consistent product for secondary processing.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Material de alimentação grande (até 1.400 mm) é direcionado para as profundezas, câmara de britagem sem asfixia através de um alimentador vibratório (opcional).
2. Ação Esmagadora: A robust eccentric shaft drives a dynamically balanced moving jaw plate in an elliptical motion, applying compressive force against a fixed jaw plate.
3. Descarga: O material triturado sai pela abertura de descarga inferior, com tamanho determinado pela configuração fechada (CSS), adjustable via hydraulic toggle adjustment.

Escopo de aplicação: Ideal para mineração de rocha dura (minério de ferro, minério de ouro), pedreiras de granito/basalto, e processamento de escória. It is designed as the first stage in a multistage reduction circuit.

Limitações: Not suitable for recycling applications with high levels of rebar or tramp metal without additional protection systems. Requires a stable concrete foundation and appropriate feed system engineering for optimal performance.

3. RECURSOS PRINCIPAIS

Sistema de ajuste de alternância hidráulica | Base Técnica: Integrated hydraulic cylinder replaces manual shims | Benefício Operacional: Enables remote CSS adjustment in under 2 minutes versus hours of manual labor; enhances safety by eliminating personnel entry into hazardous areas | Impacto do ROI: Reduz em mais de tempo de inatividade para alterações de tamanho do produto 90%, increasing plant flexibility and annual throughput.

Câmara de britagem simétrica profunda | Base Técnica: Optimized kinematics and chamber geometry derived from finite element analysis | Benefício Operacional: Promotes uniform wear across jaw dies, extends liner life by up to 30%, e garante uma gradação consistente do produto | Impacto do ROI: Lowers costperton for wear parts and reduces inventory requirements for spare liners.

Rolamentos autocompensadores de rolos para serviços pesados & Eixo excêntrico forjado | Base Técnica: Oversized bearings with high load ratings and a onepiece machined shaft | Benefício Operacional: Lida com picos de carga de material não britável; provides reliable operation under full load with minimal heat generation; extended bearing life | Impacto do ROI: Predictable maintenance intervals; eliminates premature bearing failure as a source of catastrophic downtime.

Interface de automação baseada em PLC | Base Técnica: Integrationready control system monitoring main drive amps, temperatura do rolamento, pressão hidráulica | Benefício Operacional: Allows operators to monitor crusher health in realtime and integrate into wider plant SCADA systems; enables automated overload protection | Impacto do ROI: Facilitates predictive maintenance scheduling and prevents costly damage from undetected anomalies.

Aparafusado & Doweled Main Frame Construction | Base Técnica: Stressrelieved steel sections joined with hightensile bolts on machined surfaces | Benefício Operacional: Ensures longterm structural integrity under cyclic loading; simplifies field assembly and future relocation compared to welded frames | Impacto do ROI: Reduz o tempo de instalação em aproximadamente 25% and maintains precise bearing alignment for decades.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Classe comparável) | Solução de britador de mandíbula JC5000 | Vantagem (% melhoria) |
| : | : | : | : |
| Vida útil do forro (Rocha Abrasiva)| ~450.000 toneladas por conjunto (estimado)| ~600.000 toneladas por conjunto (fieldverified) | +33% vida útil mais longa |
| Consumo de energia| Specific power draw of ~0.85 kWh/ton| Specific power draw of ~0.78 kWh/ton| Até 8% mais eficiente |
| Adjustment Downtime| 46 hours for manual shim change| <10 minutos através do sistema hidráulico| ~95% reduction in downtime |
| Rolamento L10 Vida| 25,000 hours under ideal conditions| 35,000 horas sob carga nominal| +40% increase in rated life |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: 750 – 1,500 mtph (dependente do material de alimentação & closedside setting)
Abertura de alimentação: 1,500mm x 2.000 mm (59" x 79")
Tamanho máximo de alimentação: Up to 1,400mm (55")
Impulsione a potência: 200 kW / 250 Motor elétrico HP (padrão)
Peso total: Aproximadamente 125,000 kg (275,000 libras)
Construção da Estrutura Principal: Highintegrity steel plate with bolted reinforcement
Material da mandíbula: Aço manganês premium (18% Mn)
Faixa de temperatura operacional: 30°C a +45°C (22°F a +113°F) com lubrificação padrão
Ajuste de configuração de descarga: Hydraulic system range from 200mm to 300mm

6. CENÁRIOS DE APLICAÇÃO

Hard Rock Iron Ore Mine – Australia

Desafio: A major iron ore operation faced excessive wear on their primary crusher jaws due to highly abrasive ore containing >60% sílica. Liner changes every six weeks were causing significant production bottlenecks.
Solução: Implementation of the JC5000 Jaw Crusher equipped with specially profiled quarrygrade jaw plates.
Resultados: Field data shows jaw liner life increased from approximately 350k tons to over $550k tons before replacement required—a $57$ improvement—reducing annual planned downtime events by three.

Granite Aggregate Quarry – North America

Desafio: The quarry needed to switch final product sizes frequently between road base (50milímetros) and rail ballast (65milímetros), but manual CSS adjustments took half a shift each time.
Solução: Installation of the JC5000 with its integrated hydraulic toggle adjustment system.
Resultados: The plant now performs CSS changes remotely in under $10$ minutos versus $4$ horas antes. This flexibility has allowed them to capitalize on spot market demands for different products without sacrificing primary line availability.

7. CONSIDERAÇÕES COMERCIAIS

The JC5000 Jaw Crusher is offered as part of a modular solution package:

Nível de equipamento básico: Includes crusher assembly with standard manganese jaws,acionamentos de motor,and lubrication system.
Recursos opcionais & Módulos: Motor starter VFD package,sensores de monitoramento de vibração,anel de supressão de poeira,fixed or vibrating grizzly feeder module,walkin maintenance platforms.
Pacotes de serviços: As ofertas em camadas incluem:
Basic commissioning & treinamento de operadores.
Extended warranty coverage up to $36$ meses nos principais componentes.
Inspeção anual & condition reporting program.
Guaranteed parts availability program with $48$hour emergency dispatch.
Opções de financiamento: Disponível através de instituições parceiras, incluindo locação de equipamentos ($36$60 termos do mês),estruturas próprias para aluguel,and project financing tailored for large capital expenditures.

Pricing reflects its position as premium capital equipment designed for lowest longterm cost of ownership rather than lowest initial purchase price.Investment justification is based on total costperton over an expected minimum service life exceeding $15$ anos.

8.Perguntas frequentes

1º trimestre:What existing plant infrastructure is required?
A1:The JC5000 requires a reinforced concrete foundation designed to specific dynamic load drawings provided by our engineering team.A compatible feed system capable of handling its maximum capacity is essential.Adequate overhead crane capacity ($150+ ton$) is recommended for servicing major components like the eccentric shaft assembly during planned rebuilds every $810$ years depending upon utilization rates observed within similar operations worldwide today

2º trimestre:What impact will this have on my overall plant throughput?
A2:The high capacity ($7501500 mtph$) combined with exceptional reliability directly increases upstream mining or feeding efficiency while reducing bottlenecks downstream due primarily because it produces more consistent product sizes which allows secondary cone crushers operate optimally at their own designed settings leading ultimately towards higher overall circuit stability measured via increased availability percentages typically ranging between two percent ($2\%$) up five percent ($5\%$) according data collected across multiple sites globally since introduction last decade ago

3º trimestre:Quais são os prazos de entrega típicos?
A3:Crushers are builttoorder following receipt firm purchase order.Current lead time stands at approximately nine months subject raw material supply chain conditions prevailing at time order placement however expedited delivery options may sometimes be available depending upon project schedule requirements discussed during initial quotation phase prior commitment being made either party involved transaction process itself

4º trimestre:Que treinamento você oferece?
A4:A comprehensive training program accompanies every installation covering safe operation routine maintenance procedures troubleshooting common issues using actual machine supplied customer site sessions conducted both classroom handson formats lasting total three days duration additionally detailed manuals videos remain accessible online throughout ownership period thereafter ensuring knowledge transfer complete effective manner possible given constraints present modern industrial environments today

Q5:What happens if we encounter tramp metal or an uncrushable object?
A5:The hydraulic toggle system serves dual purpose acting also as automatic release mechanism should uncrushable object enter chamber When pressure exceeds preset limit toggle cylinder relieves allowing moving jaw retreat protecting main frame bearings shaft other critical components from catastrophic damage Once object cleared normal operation resumes quickly minimizing potential disruption caused such events significantly compared designs lacking this protective feature entirely