1. ABERTURA ACIONADA POR PAINPOINT

Are escalating operational costs and unplanned downtime eroding your quarry or mine’s profitability? Primary crushing stages present persistent challenges that directly impact your bottom line. Considere estes obstáculos operacionais comuns:
Tempo de inatividade excessivo para manutenção: Frequent liner changes and mechanical adjustments halt your entire processing line, custando milhares por hora em perda de produção.
Unpredictable Wear Life & High Parts Costs: Inconsistent abrasion resistance in critical components leads to variable replacement cycles and spiraling consumables expenditure.
Manuseio inconsistente de feeds: Bridging, packing, or inefficient crushing of slabby material reduces average throughput and increases load on downstream equipment.
Alto Consumo de Energia por Tonelada: Older or inefficient crusher designs consume disproportionate power, making energy a major variable cost.
Rigidez & Foundation Stress: Inadequate structural design transmits excessive vibration and stress, leading to costly structural repairs and alignment issues.

Is your primary crusher a reliable asset or a recurring capital drain? The solution lies in selecting a machine engineered not just to crush, but to optimize total cost of ownership.

2. VISÃO GERAL DO PRODUTO

The JC5000 Jaw Crusher is a highcapacity, robustly engineered singletoggle jaw crusher designed for heavyduty primary crushing applications in mining, pedreira, e reciclagem de construção em grande escala. Its design prioritizes mechanical simplicity for reliability and ease of maintenance.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Grande runofmine (ROM) material is directed into the deep, nonchoking crushing chamber via vibrating grizzly feeder.
2. Ação Esmagadora: The aggressive elliptical stroke of the single toggle jaw applies high inertia force, effectively reducing even the hardest granite, basalto, or abrasive ores.
3. Descarga & Clearance: The hydraulic toggle system allows for quick adjustment of the closedside setting (CSS) and provides automatic tramp iron release, clearing the chamber without stopping the crusher.
4. Continuous Processing: Crushed product is consistently discharged onto the main conveyor at a calibrated size, pronto para processamento secundário.

Escopo de aplicação: Ideal for hightonnage stationary primary crushing stations processing hard rock (compressive strength >250 MPa), blasted quarry stone, e concreto de demolição. It is suited for operations targeting consistent output of 750+ MTPH.

Limitações: Not designed for ultrafine product sizing; secondary or tertiary crushing circuits are required for final aggregate shaping. Requires a stable concrete foundation and planned feed control for optimal performance.

3. RECURSOS PRINCIPAIS

Geometria de Câmara Profunda | Base Técnica: Optimized nip angle and long crushing stroke | Benefício Operacional: Enables higher capacity by drawing material deep into the chamber for effective reduction on each cycle | Impacto do ROI: Increases throughput by up to 15% over comparable models with shallower chambers

Projeto de rolamento de rolo para serviços pesados | Base Técnica: Spherical selfaligning roller bearings with large diameter shafts | Benefício Operacional: Supports higher load capacities and tolerates momentary shock loads from uncrushables | Impacto do ROI: Prolonga a vida útil do rolamento em um valor estimado 30%, reducing replacement frequency and associated downtime

Alternar Hidráulico & Sistema de ajuste | Base Técnica: Replaceable hydraulic cylinder for tensioning and clearing | Benefício Operacional: Allows operators to adjust CSS safely in minutes and clear blockages without manual intervention | Impacto do ROI: Cuts downtime for routine adjustments by over 80% versus traditional shim systems

Aparafusado & Wedged Frame Construction | Base Técnica: Fabricated steel sections joined with hightensile bolts and locking wedges | Benefício Operacional: Provides exceptional rigidity, reduces stress concentrations, and simplifies field assembly/transport | Impacto do ROI: Minimizes frame fatigue failures; reduces foundation costs due to lower transmitted vibration

Symmetrical Reversible Jaw Dies | Base Técnica: Identical corrugation profiles allow dies to be rotated endtoend or swapped sidetoside | Benefício Operacional: Doubles usable wear life per die set by utilizing multiple wear zones before changeout | Impacto do ROI: Lowers consumable costs per ton crushed by approximately 40%

Integrated Motor Mount & Proteção de unidade | Base Técnica: Unified base frame includes motor mount and full perimeter guarding | Benefício Operacional: Simplifies installation alignment, enhances site safety compliance, protects drive components from debris | Impacto do ROI: Reduces installation time/cost by ~20% and eliminates need for custom guarding fabrication

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Classe comparável) | Solução de britador de mandíbula JC5000 | Vantagem (% Melhoria) |
|||||
| Average Liner Life | 450,000 550,000 toneladas (Granito Abrasivo) | 650,000 750,000 toneladas (Granito Abrasivo) | +25% |
| Tempo de ajuste CSS | 46 horas (shim system) | <30 minutos (hydraulic system) | 90% |
| Power Consumption per Ton ~0.85 1.0 kWh/t ~0.72 0.78 kWh/t |15% |
| Annual Availability Target ~92% ~95% |3 pontos percentuais |
| Tramp Iron Clearance Manual removal / system stop Automated hydraulic release without stop Eliminates associated downtime |

Data based on internal field performance audits versus published data from key competitors in the 500600mm feed size class.

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1500mm x 2000mm (59" x 79")
Tamanho máximo de alimentação: 1250milímetros (49")
Faixa de configuração do lado fechado: 175mm 300 mm (7" 12")
Faixa de capacidade (Varies by Material & CSS): Até 1,750 MTPH
Requisitos de energia da unidade: Twin TEFC motors totaling ~375 kW (~500 HP)
Peso total (Apenas triturador): Approximately ~145 metric tons
Construção da Estrutura Principal: Highstrength fabricated steel plate with stressrelieved welds
Swing Jaw Die Material Options: Standard AR400 / Premium AR500 / Custom Manganese Steel alloys
Faixa de temperatura operacional: 30°C a +45°C (22°F a +113°F) with standard lubrication package
Discharge Height (from base): Configurable between ~2m ~3m

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Challenge A major aggregate producer needed to increase primary circuit throughput by over 30% but was constrained by existing plant footprint and high maintenance windows on their legacy jaw crushers.
Solution Installation of one JC5000 Jaw Crusher as the new primary unit with a customdesigned feed hopper to interface with existing infrastructure.
Results Throughput increased by an average of ~~35%. Liner changeout intervals extended from ~~8 weeks to ~~12 weeks under similar conditions. The hydraulic adjustment system reduced quarterly setting maintenance from two shifts to under two hours.

Iron Ore Processing Plant Retrofit

Challenge An aging gyratory primary crusher suffered from chronic reliability issues and excessive energy consumption (~1.1 kWh/t), contributing to unsustainable operating costs.
Solution Phased replacement with a JC5000 Jaw Crusher during a planned plant shutdown period.
Results Plant availability improved immediately postinstallation due to reduced mechanical complexity. Specific energy consumption dropped to ~~0~~75 kWh/t measured over six months of operation resulting in significant annual power cost savings at scale

7 CONSIDERAÇÕES COMERCIAIS

The JC5000 Jaw Crusher is offered as part of a comprehensive modular station solution or as a standalone unit.

Níveis de preços:
Base Equipment Price Includes crusher assembly motor drives flywheels guards basic tool kit
Enhanced Package Base + automated grease lubrication system wear monitoring sensors spare parts kit
Turnkey Station Enhanced Package + customengineered feed module discharge conveyor walkways platforms electrical control panel

Recursos opcionais:
Dust suppression spray system onboard jaw die lifting device special corrosion protection packages remote monitoring telematics gateway

Pacotes de serviços:
Standard Warranty months parts months labor on rotating assemblies
Extended Service Plan years scheduled inspections priority parts dispatch discounted labor rates
Full Maintenance Contract Fixed annual fee covering all scheduled maintenance wear parts replacements excluding major structural components

Financing Options Available through OEMaffiliated partners include capital lease operating lease longterm rentaltoown structures tailored support available for greenfield project financing

8 Perguntas frequentes

What are the foundation requirements for the JC5000?
Detailed civil drawings are provided specifying load distribution dynamic forces anchor bolt locations A reinforced concrete foundation designed by your contractor based on our specifications is mandatory

Can we use our existing feeder conveyor motors?
Integration is possible but requires engineering review Our team can assess compatibility of your existing equipment drive pulleys gear reducers electrical supply with the JC5000s requirements

How does the hydraulic toggle affect tramp metal protection?
The system maintains constant pressure during normal operation If an uncrushable object enters it automatically releases pressure allowing the moving jaw retract Once object passes pressure resets restoring original CSS without manual intervention stopping process

What is lead time from order placement commissioning?
Standard lead time months For expedited delivery inquire about our FastTrack program which may reduce lead time Optional supervised commissioning training included Enhanced Package Turnkey Station purchases

Are performance guarantees offered?
Yes guaranteed minimum capacity figures are provided specific contract based agreed feed material characteristics CSS Guarantees also cover mechanical availability first months operation subject proper maintenance adherence