1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Para gerentes de fábrica e empreiteiros de engenharia, the primary jaw crusher is a critical—and often problematic—bottleneck. Os desafios comuns incluem:
Custos excessivos de peças de desgaste: Premature failure of jaw dies due to improper kinematics or lowquality materials, levando a frequentes, substituições dispendiosas e mudanças trabalhosas.
Tempo de inatividade não programado: Structural fatigue or bearing failures from uncrushable materials or shock loads, halting your entire processing line for days.
Taxa de transferência inconsistente & Formato do produto: Inefficient crushing chamber designs that produce excessive fines or slabby product, reducing downstream efficiency and final product value.
Alto consumo de energia: Inefficient drive systems and heavy, powerintensive components that significantly increase your costpertonne.

How do you select a primary crusher that delivers not just promised capacity, but predictable operating costs and sustained availability? The solution requires a focus on engineered durability and intelligent design.

2. VISÃO GERAL DO PRODUTO

O britador de mandíbula JC5000 é um britador de mandíbula de alta capacidade, Britador primário singletoggle projetado para a mineração mais exigente, pedreira, and heavyduty construction applications. Its robust design is built to process hard rock, minério, and demolition concrete with maximum reliability.

Fluxo de Trabalho Operacional:
1. Alimentar & Compressão Inicial: Material de alimentação grande (up to 1.5m cube) entra nas profundezas, câmara de britagem sem asfixia.
2. Golpe Esmagador Agressivo: O mecanismo singletoggle de alta força aciona a mandíbula móvel em um movimento elíptico, applying compressive force efficiently.
3. Descarga & Liberação: The steep nip angle and optimized discharge setting facilitate rapid material evacuation, preventing chokepoints and promoting high throughput.
4. Integração de Sistemas: The crusher interfaces with vibrating grizzly feeders and downstream conveyors for a continuous feed system.

Escopo de aplicação: Ideal for stationary primary crushing plants processing granite, basalto, minério de ferro, minério de cobre, and recycled aggregates. It is suited for hightonnage operations (>800 mtph) requiring a top feed size up to 1500mm.

Limitações: Not designed for abrasive recycling applications without specific liner options. Requires a solid foundation and appropriate feeding equipment to achieve stated performance.

3. RECURSOS PRINCIPAIS

Conjunto de rolamento de rolo para serviços pesados | Base Técnica: Rolamentos autocompensadores de rolos autocompensadores com eixos de grande diâmetro | Benefício Operacional: Handles high radial and thrust loads from tough crushing conditions; extends bearing life by up to 3x compared to standard bearings | Impacto do ROI: Reduz o risco de falha catastrófica do rolamento; lowers maintenance frequency and associated labor costs.

Hydraulic Wedge Adjustment System | Base Técnica: Dualacting hydraulic cylinders replace manual shim adjustment | Benefício Operacional: Allows closedside setting (CSS) adjustments to be made quickly, com segurança, and accurately in minutes versus hours | Impacto do ROI: Maximizes plant uptime during product changeovers; improves operator safety by eliminating manual handling.

Geometria otimizada da câmara de britagem | Base Técnica: Computermodeled kinematics with a steep nip angle and deep symmetrical chamber | Benefício Operacional: Delivers higher reduction ratios per pass; produces a more consistent product shape with less slabby material | Impacto do ROI: Increases effective capacity of downstream circuits; improves final product cubicity for higher market value.

Revestimentos de desgaste BoltOn | Base Técnica: Modular liner design with replaceable cheek plates manufactured from abrasionresistant steel | Benefício Operacional: Simplifica a substituição do revestimento; protects the main frame structure from wear indefinitely | Impacto do ROI: Drastically reduces longterm capital asset depreciation; cuts liner changeout time by over 40%.

PLCIntegrated Overload Protection | Base Técnica: Hydraulic toggle plate with pressure sensors linked to the plant control system | Benefício Operacional: Automatically releases tramp metal or uncrushable material; resets without manual intervention | Impacto do ROI: Prevents costly damage to the pitman and bearings; avoids hours of unscheduled downtime per event.

Acionamento direto via VBelts & TEFC Motor | Base Técnica: Hightorque motor connected via multiple Vbelts to a heavyduty flywheel | Benefício Operacional: Transmissão de energia suave que absorve flutuações de carga; standard motor compatibility simplifies sourcing and replacement | Impacto do ROI: Lower installed cost compared to fluid couplings; improved energy efficiency under variable load conditions.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Classe comparável) | Solução de britador de mandíbula JC5000 | Vantagem (% Melhoria) |
| : | : | : | : |
| Mandíbula morre vida (Granito Abrasivo) | ~450.000 toneladas por conjunto (based on competitor data sheets)| ~550,000 tonnes per set (fieldverified average)| +22% in wear material cost/tonne |
| Intervalo de manutenção do rolamento (MTBF)| 8,000 10,000 horário de funcionamento| 14,000+ horário de funcionamento (projetado)| +40% in service life |
| Tempo de ajuste CSS (Mechanical to Mechanical)| 46 hours with crew of two| <1 hour with single operator| 80% in downtime for adjustment |
| Consumo de energia por tonelada triturada| Benchmark of 100%| Average of 9295% (dependente do site)| 5% para 8% nos custos de energia |
| Peso total / Structural Mass Index| Benchmark of 100% for rated capacity| Index of ~115% (higher masstocapacity ratio)| +15% in structural rigidity & fatigue resistance |

Mean Time Between Failures based on industry lubrication schedules.
Mass index compares total machine weight relative to throughput capacity as an indicator of robustness.

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1500mm x 2.000 mm (59" x 79")
Tamanho máximo de alimentação: Up to 1500mm cube (59")
Faixa de configuração do lado fechado: 200mm 300 mm (8" 12")
Faixa de capacidade: Até 1650 mtph (dependente do material de alimentação & CSS)
Requisitos de energia da unidade: 375 kW /500 HP TEFC electric motor
Peso total (Apenas triturador): Approximately ~145,000 kg (~320,000 lbs)
Construção da Estrutura Principal: Fabricated steel plate with stressrelieved welds; AR steel liners at wear points.
Faixa de temperatura ambiente operacional: 20°C a +45°C (4°F a +113°F) com lubrificação padrão.
Discharge Conveyor Recommendation: Minimum width of 1800mm (72") at recommended speed.

6. CENÁRIOS DE APLICAÇÃO

Hard Rock Quarrying – Granite & Basalt Primary Crushing

Challenge A major aggregate producer faced excessive downtime from jaw die changes every ~400k tonnes and frequent adjustments for product gradation changes.
Solution Installation of one JC5000 Jaw Crusher as the new primary unit featuring bolton liners and hydraulic wedge adjustment.
Results Field data shows jaw die life extended by approximately +22%, achieving over $50k annual savings in wear parts alone. CSS adjustments now take under one hour versus half a shift each time they occur.

Mineral Processing – Primary Iron Ore Crushing

Challenge An iron ore operation required higher throughput after mine expansion but had space constraints limiting plant footprint increases.
Solution Replacing two older jaw crushers with one highercapacity JC5000 unit due its deeper chamber allowing greater volume reduction per pass.
Results Plant throughput increased by approximately +30%. The consolidated footprint reduced civil works costs by an estimated $200k USD while lowering overall energy consumption per tonne processed by nearly 7%.

Major Infrastructure – Tunnel Boring Muck Processing

Challenge A largescale tunneling project needed an ultrareliable primary crusher located underground to process mixed geology muck continuously under strict schedule constraints.
Solution Deployment of the JC5000 configured with PLCintegrated overload protection specifically sized for conveyor transport out of the tunnel shaft.
Results The hydraulic toggle system successfully cleared multiple uncrushable objects automatically preventing an estimated >120 hours of potential downtime over the project lifecycle maintaining critical path schedule integrity

7 CONSIDERAÇÕES COMERCIAIS

The JC5000 Jaw Crusher is offered as part of a complete modular crushing station or as a standalone unit for integration into existing plants

Níveis de preços de equipamentos:
1 Base Unit Includes crusher mainframe drive motor flywheel guards basic tool kit
2 Plant Ready Package Adds hydraulic power pack for adjustment integrated walkways ladders preinstalled lubrication system
3 Customized Application Package Includes applicationspecific jaw die metallurgy special guarding environmental packages dust suppression interfaces

Recursos opcionais:
• Automated Greasing System
• Rock Level Sensor Integration
• Special AR Steel Grades for Cheek Plates
• SkidMounted Modular Frame

Pacotes de serviços:
• Commissioning Supervision Standard package includes field technician support during startup Extended package includes operator training performance verification testing
• Preventive Maintenance Contracts Tiered plans offering scheduled inspections parts kits priority support based on annual operating hours

Financing Options Available through our partners including equipment leasing capital loans rentaltoown structures tailored project financing

8 Perguntas frequentes

Q What are the foundation requirements for installing this crusher?
A Detailed civil drawings are provided requiring reinforced concrete foundations designed dynamic loads exceeding static weight Consult engineering specifications early site planning phase

Q Can this crusher handle recycled concrete brick asphalt?
A While capable processing these materials we recommend consultation our engineering team specify appropriate jaw die metallurgy potentially install additional scalping preclean scrap metal Prolonged processing highly abrasive recycled materials may impact wear life expectations

Q How does hydraulic wedge adjustment compare traditional shim systems?
A Hydraulic wedges allow remote controlled adjustment from outside crusher improving safety speed Process takes minutes versus hours required manually add remove steel shims providing precise repeatable control over product size

Q What is typical delivery lead time after order placement?
A Lead times vary based configuration current production schedule Standard Plant Ready Package typically ships within months order confirmation Customized packages may require additional engineering manufacturing time We provide firm delivery schedule upon order confirmation

P As peças sobressalentes estão prontamente disponíveis em todo o mundo??
A We maintain regional inventory hubs key wear components structural parts Critical items like bearings shafts stocked strategic locations ensure availability Most standard wear parts shipped within business days emergency orders