1. ABERTURA ACIONADA POR PAINPOINT

Are escalating operational costs and unpredictable downtime eroding your quarry or mine's profitability? Primary crushing stages present significant financial risks, incluindo:

Tempo de inatividade excessivo para manutenção: Frequent liner changes and component wear halts your entire processing line, custando milhares por hora em perda de produção.
Alto Consumo de Energia por Tonelada: Inefficient crushing chambers and outdated drive systems lead to unsustainable power costs, impactando diretamente seus resultados financeiros.
Unplanned Breakdowns from Tramp Metal: Unseen contaminants cause catastrophic damage to crusher internals, resultando em contas de reparos de seis dígitos e interrupções prolongadas.
Gradação inconsistente do produto: An unstable or poorly designed swing jaw motion produces irregular output, causing bottlenecks in secondary circuits and reducing final product quality.
Rigid Configurations Limiting Flexibility: Fixed plant designs cannot adapt to changing feed materials or new product specifications without major capital expenditure.

Como garantir a confiabilidade da britagem primária e ao mesmo tempo controlar o custo total de propriedade? The solution requires a machine engineered not just for peak performance, mas para sustentado, predictable operation under continuous heavy load.

2. VISÃO GERAL DO PRODUTO

O JC5000 é um equipamento de alta capacidade, robustly constructed singletoggle jaw crusher engineered for the most demanding primary crushing applications in mining, heavyduty quarrying, e produção agregada em grande escala. Its design focuses on delivering maximum uptime and the lowest cost per tonne in its class.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Grande material runofmine (até 1,5 m de comprimento de borda) é direcionado para as profundezas, câmara de britagem sem asfixia.
2. Ação Esmagadora: A highinertia flywheel and an aggressive elliptical swing jaw motion apply intense compressive force to the feed material against a fixed jaw.
3. Descarga: Crushed material exits at the bottom of the chamber, with a fully adjustable closedside setting (CSS) determining final product size without requiring changes to the discharge point.

Escopo de aplicação & Limitações:
Escopo: Ideal para hard rock (granito, basalto), minérios abrasivos, e concreto reciclado/resíduos de demolição. Suited for stationary plants or large mobile tracked units requiring throughputs from 750 para 1,500 mtph depending on material and CSS.
Limitações: Não projetado para pegajoso, plastic clays or as a secondary/tertiary crusher for already small feed. Requer um estábulo, reinforced concrete foundation and significant plant footprint.

3. RECURSOS PRINCIPAIS

Geometria de Câmara Profunda & Steep Nip Angle | Base Técnica: Optimized kinematics for increased capacity and reduced bridging | Benefício Operacional: Handles larger feed blocks with fewer stoppages for clearing | Impacto do ROI: Os dados de campo aparecem até 15% higher throughput versus comparable crushers with similar power input.

Projeto de rolamento de rolo para serviços pesados | Base Técnica: Rolamentos autocompensadores de rolos autocompensadores no eixo excêntrico e no assento articulado | Benefício Operacional: Supports higher radial and thrust loads with lower friction than bronze bushes | Impacto do ROI: Increases bearing service life by an estimated 40%, reduzindo custos de estoque de peças sobressalentes.

Ajuste de alternância hidráulica & Limpeza | Base Técnica: Integrated hydraulic cylinder for toggle plate adjustment and overload relief | Benefício Operacional: Enables remote CSS adjustment in minutes and automatic release of tramp metal | Impacto do ROI: Eliminates manual shim changes, salvando 23 hours of labor per adjustment and preventing damage from uncrushables.

Aparafusado (Não Soldado) Construção de moldura | Base Técnica: Highstrength cast steel sections joined via machined flanges and hardened bolts | Benefício Operacional: Elimina concentrações de tensão da soldagem; permite a substituição seccional se estiver gravemente danificada | Impacto do ROI: Provides a demonstrably longer structural life than welded frames, protegendo o valor dos ativos a longo prazo.

Acionamento direto via VBelts & Tensioner | Base Técnica: Crusher driven by multiple Vbelts from a standard TEFC motor | Benefício Operacional: Simple maintenance; belt slip acts as a mechanical fuse against severe shock loads | Impacto do ROI: Lower installation cost vs gearbox drives; common industrial motor reduces procurement lead time.

Matrizes de mandíbula reversíveis simétricas | Base Técnica: Identical corrugation profiles allow dies to be rotated endforend or swapped toptobottom | Benefício Operacional: Utilizes up to 100% of wear material before replacement; estende os intervalos de manutenção em até 30%| Impacto do ROI: Directly reduces consumable costs per tonne crushed.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Médias dos concorrentes) | Solução de britador de mandíbula JC5000 | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | ~8590% (agendado & paradas não programadas)| >94% (based on field performance data)| +510% melhoria |
| Vida útil do forro (Granito Abrasivo) | ~180.000 220,000 toneladas por conjunto| Até 280,000 tonnes per set with symmetrical dies| +2530% melhoria |
| Energy Consumption @ CSS 200mm| ~0,85 1.0 kWh/tonelada| Average measured at 0.78 kWh/tonelada| ~1520% de melhoria |
| Tempo de recuperação do metal residual| Compensação manual / disassembly (48 horas)| Limpeza hidráulica (<10 minutos)| ~98% reduction in downtime |

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1500mm x 1300 mm (59" x 51")
Tamanho máximo de alimentação: Comprimento de borda de até 1250 mm (49")
Faixa de configuração do lado fechado: 150mm 300 mm (6" 12")
Faixa de capacidade: Dependent on material & CSS; typically between 750 1500 mtph
Requisitos de energia da unidade: Standard configuration requires a single electric motor rated at minimum of kW / HP
Peso total (Apenas triturador): Aproximadamente kg / libras
Principais especificações de materiais: Estrutura de aço fabricada de alta resistência; Matrizes de mandíbula de aço manganês; Eixo excêntrico de liga de aço forjado; Cast steel swing jaw body.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C (4°F a +113°F). As vedações contra poeira são padrão; sistemas opcionais disponíveis para ambientes extremos.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Desafio: Um grande produtor agregado precisava aumentar o rendimento do circuito primário em mais de % but was constrained by existing foundation space and high energy costs from their older crushers.
Solution Implementation of one JC5000 Jaw Crusher replaced two older units due to its higher capacitytofootprint ratio.
A produtividade dos resultados aumentou em % while specific energy consumption dropped by %. The consolidated setup freed plant space for additional screening capacity.

Atualização da planta de processamento de minério de ferro

Challenge Unpredictable tramp metal from haulage vehicles caused repeated bent toggle plates and eccentric shaft damage on the primary crusher leading to days of unplanned downtime annually.
Solution Installation of a JC5000 equipped with the hydraulic toggle system provided automatic overload protection
Results In months since commissioning zero instances of mechanical damage from uncrushables have occurred The hydraulic system has cleared events successfully maintaining continuous operation

7 CONSIDERAÇÕES COMERCIAIS

O britador de mandíbula JC5000 é oferecido em vários níveis de configuração:

Base Configuration Includes core crusher assembly standard manganese jaws motor base v belts guards

Premium Configuration Adds hydraulic toggle adjustment system automated grease lubrication integrated temperature monitoring sensors

Customization Options Available upon request include special wear alloys alternative shaft sealing arrangements custom discharge chutes or integration packages with specific feeders

Service Packages Extended warranty plans scheduled inspection services remote monitoring connectivity options are available

Financing Options Flexible commercial structures including outright purchase capital lease or operating lease agreements can be arranged through our financial partners

8 Perguntas frequentes

What is the expected operational lifespan of the JC5000 main frame Industry testing demonstrates that the bolted non welded frame construction can exceed years in continuous hard rock service when maintained according to protocol

Can we use our existing feeder grizzly screen motors with this crusher The JC5000 can be integrated into existing plants engineering contractors will provide interface drawings Power requirements must be verified against your current electrical infrastructure

How does the hydraulic toggle affect maintenance schedules It eliminates manual shimming reducing routine adjustment time from hours to minutes It does not replace the need for regular inspections of wear parts lubrication system checks

What is the typical delivery lead time For standard configurations lead time is approximately months from order confirmation Customized units require additional engineering time which will be specified during project quotation

Are performance guarantees offered Yes guaranteed minimum throughput figures are provided based on your specific feed material analysis as part of our pre sale technical review process