Targeting Primary Crushing Inefficiency: The High Cost of Compromise

Are your aggregate production or mining operations constrained by the primary crushing stage? Inefficient jaw crusher performance directly impacts your entire downstream process, manifesting as:

Tempo de inatividade excessivo para manutenção: Frequent liner changes and unplanned stops for blockages can consume 1520% of available operating hours, costing tens of thousands in lost throughput.
Gradação de produto imprevisível: Inconsistent feed opening dynamics and wear lead to poor size distribution, overworking secondary crushers and reducing final product yield.
Custos operacionais em espiral: Premature component wear, alto consumo de energia por tonelada, and high labor intensity for routine servicing erode profit margins.
Flexibilidade de alimentação limitada: Inability to handle a varied mix of feed materials (por exemplo, abrasive basalt, recycled concrete with rebar, highclay ores) forces production to slow down or stop.

Is your primary crusher a reliable asset driving profitability, or a recurring source of bottleneck and expense? The solution lies in specifying equipment engineered not just to crush, mas para otimizar o custo total de propriedade.

Visão geral do produto: JC5000 HeavyDuty Jaw Crusher

The JC5000 is a robust, singletoggle jaw crusher engineered for highcapacity primary crushing in demanding quarrying, mineração, e aplicações de reciclagem de demolição. Its design focuses on delivering consistent throughput with minimized operational intervention.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Grande (500mm x 250mm) feed opening accepts runofmine or runofquarry material directly from haul trucks.
2. Esmagamento por compressão: A steep nip angle and aggressive crushing motion applies intense compressive force to fracture material against the fixed jaw plate.
3. Descarga & Liberação: The hydraulically assisted toggle system provides quick reversal of the moving jaw to clear blockages and assist in tramp metal release without stopping the crusher.
4. Transporte de Produto: Crushed material exits at a consistent CSS (Configuração lateral fechada), typically between 75mm 150mm, pronto para processamento secundário.

Escopo de aplicação & Limitações:
Ideal para: Hard rock quarries (granito, basalto), mediumscale mining operations, largescale construction waste recycling plants.
Limitações: Not designed for ultrafine grinding or as a standalone solution for finished aggregate. O tamanho máximo de feed recomendado é 80% da dimensão da abertura de alimentação. Requires a stable foundation and appropriate upstream feeding equipment.

Recursos principais: Engenharia para Superioridade Operacional

Sistema de ajuste de alternância hidráulica | Base Técnica: Integrated hydraulic cylinder replaces mechanical shims | Benefício Operacional: CSS adjustment takes minutes versus hours, performed safely from ground level | Impacto do ROI: Reduz o tempo de inatividade para trocas de produtos em até 90%, increasing annual utilization.

Eixo excêntrico QuarryGrade | Base Técnica: Forged from highintegrity alloy steel, suportado por rolamentos autocompensadores de rolos superdimensionados | Benefício Operacional: Sustains peak load under shock conditions; bearings run cooler with extended L10 life | Impacto do ROI: Eliminates premature shaft failure; field data shows bearing service intervals extended by 40%.

Geometria de Câmara Otimizada | Base Técnica: Computermodeled kinematics create an aggressive nip angle and deep crushing chamber | Benefício Operacional: Enhances throughput capacity and promotes slabby material breakage over flaking | Impacto do ROI: Entrega até 10% more tons per hour at equivalent power draw compared to previous generation designs.

Construção de estrutura para serviços pesados | Base Técnica: Fabricated from stressrelieved steel plate with reinforced ribbing at all highstress points | Benefício Operacional: Provides longterm alignment stability under cyclical loading, protegendo componentes internos | Impacto do ROI: Mitigates risk of frame fatigue cracking, garantindo a integridade estrutural ao longo de um 15+ ano de vida útil.

Segurança aprimorada & Facilidade de manutenção | Base Técnica: Centralized grease points; accessible cheek plate bolts; guarding integrated into structure | Benefício Operacional| Routine maintenance tasks are faster and safer for technicians| Impacto do ROI| Lowers scheduled maintenance labor hours by an estimated 25%, improving site safety compliance.

Vantagens Competitivas: Ganhos mensuráveis ​​de desempenho

The JC5000 Jaw Crusher is designed to outperform conventional solutions across critical metrics.

| Métrica de desempenho | Padrão da Indústria (Classe comparável) | Desempenho documentado da solução JC5000 | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | ~85% (ajuste de fatoração & blockage downtime)| >92% (with hydraulic toggle & compensação) | +8% |
| Vida útil do forro (Rocha Abrasiva) | ~120.000 toneladas por conjunto (Mn14%)| ~150,000 tons per set (Mn18% optional) | +25% |
| Eficiência Energética (kWh/tonelada)| Varia muito; baseline = 1.0x factor| Field data shows consistent reduction averaging ~0.9x factor |10% |
| Tempo de ajuste CSS| 24 horas com tripulação| <30 minutes with single operator |87% |

Especificações Técnicas

Abertura de alimentação: 500mm x 250mm
Tamanho máximo de alimentação: 400milímetros
Faixa de configuração do lado fechado: 75mm 150mm
Faixa de capacidade: 180 350 toneladas por hora (depende do material de feed e CSS)
Requisitos de energia da unidade: 75kW /100HP electric motor (padrão)
Peso do britador (excluindo motor): Aproximadamente 16 toneladas métricas
Principais especificações de materiais:
Frame Fabrication Grade Steel
Jaw Plates Premium manganese steel (Mn14% standard; Mn18%, Mn22% optional)
Eccentric Shaft Forged EN24/34CrNiMo6 equivalent
Bearings Spherical roller bearings; Timken/SKF/FAG grade
Faixa de temperatura operacional: 20°C to +40°C with standard lubricants.
Dimensões (C x L x A): ~3.5m x 2.8m x 2.9m

Cenários de aplicação

Granite Quarry Expansion Project Challenge:

A quarry needed to increase primary circuit throughput by 30% without expanding its footprint or major civil works. Their existing crusher created bottlenecks due to slow adjustment times and frequent liner wear checks.

Solução:

Implementation of one JC5000 Jaw Crusher as the new primary unit. Key features utilized were the hydraulic toggle for rapid product sizing changes between road base and rail ballast production runs.

Resultados:

Throughput goals were met within the first quarter. The site manager reported a 22% reduction in weekly labor hours dedicated to crusher maintenance and adjustments, reallocating personnel to other areas.

C&D Recycling Plant Upgrade Challenge:

A recycling plant processing mixed demolition waste faced excessive downtime from uncrushable materials jamming the primary jaw, requiring full shutdowns and manual clearing several times weekly.

Solução:

Replacement with a JC5000 Jaw Crusher equipped with an automatic hydraulic tramp release system integrated into the toggle mechanism.

Resultados:

Blockage events requiring full shutdown were virtually eliminated. The plant recorded a 17% increase in monthly processed volume due to reduced stoppages while protecting downstream conveyors from metal damage.

Considerações Comerciais

Equipment pricing is structured around core configuration:

1. Base Machine Tier Includes crusher frame assembly drive sheave flywheels standard manganese liners guards lubrication system

2 Pacotes de recursos opcionais
Hydraulic Toggle Adjustment Kit Automatic Tramp Release System HeavyDuty Skid Base Frame Belt Drive Guard Package HigherGrade Manganese Liners Mn18Mn22

3 Service Support Packages Proactive maintenance plans are available including scheduled inspections parts kits priority technical support Extended warranty options can be negotiated based on application review

4 Financing Options Flexible commercial terms are offered through partnered financial institutions including equipment leasing capital loan structures or rentaltopurchase agreements tailored to project cash flow

Perguntas frequentes

What power supply is required for the JC5000 A standard 75kW 400V50Hz3phase electric motor is supplied Can it be configured for diesel drive Yes skidmounted diesel drive packages are available as an option

How does the hydraulic toggle system affect reliability The system simplifies mechanics replacing dozens of manual shims It uses proven industrial hydraulic components designed specifically for highshock environments reliability data indicates no reduction in overall system uptime

What is the lead time on replacement wear parts Commonly used parts like jaw plates cheek plates are typically held in regional stock centers with availability within 48 weeks Nonstock items have a manufacturing lead time communicated upon order

Can the JC5000 handle wet sticky clayladen material While capable performance will be reduced compared to dry rock We recommend site evaluation For severe clay applications pre screening or grizzly feeding should be considered

What commercial terms are available Minimum order quantity is one 1 unit We offer comprehensive commercial support including FOB CIF DAP delivery terms based on customer location Full payment letters of credit are standard structured payment plans can be discussed