1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de lucro agregadas ou de mineração? Primary crushing is the foundation of your material processing circuit, and its failures cascade through your entire operation. Considere estes desafios comuns:
Tempo de inatividade não programado: Bearing failures or component wear can halt production for days, costing tens of thousands in lost throughput and urgent repair logistics.
Altos custos operacionais por tonelada: Consumo excessivo de energia, coupled with frequent replacement of wear parts like jaw plates, directly increases your cost per ton of processed material.
Gradação inconsistente do produto: An unstable or inefficient crushing chamber leads to poor size reduction, increasing recirculating load and overworking downstream equipment.
Inflexibilidade Rígida: Fixed configurations struggle to adapt to varying feed materials or changing final product requirements, forçando compromissos operacionais.

Is your primary crusher a reliable asset or a persistent bottleneck? The solution requires engineering that prioritizes durability, eficiência, and intelligent design to protect your bottom line.

2. VISÃO GERAL DO PRODUTO

The Jc5000 is a highcapacity, robustly engineered singletoggle jaw crusher designed for heavyduty primary crushing in mining, pedreira, e aplicações de reciclagem de construção em grande escala. Its core function is the reliable reduction of large (até 1300 mm) feed material into a consistent, produto agregado grosso.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large runofmine or quarryrun rock is directed into the deep, abertura de alimentação não sufocante.
2. Ação Esmagadora: The aggressive elliptical stroke of a mechanically simple singletoggle design applies high inertia forces to compress and fracture material against the fixed jaw.
3. Descarga & Liberação: O material triturado sai pela abertura de descarga na parte inferior; the design facilitates rapid clearance of crushed product to maintain throughput.

Escopo de aplicação: Ideal para hard rock (granito, basalto), minérios abrasivos, e concreto de demolição. It is engineered as a stationary primary unit for hightonnage fixedplant operations.

Limitações: Not suitable as a mobile or portable unit due to size and weight. For processing highly sticky or claybound materials without prescreening, a different primary solution may be recommended.

3. RECURSOS PRINCIPAIS

Estrutura para serviço pesado & Rolamentos autocompensadores de rolos | Base Técnica: Análise de Elementos Finitos (FEA) distribuição de tensão otimizada | Benefício Operacional: Unmatched structural integrity under peak loads; bearings handle both radial and axial forces | Impacto do ROI: Extended service life under severe conditions reduces risk of catastrophic frame failure and associated capital replacement costs.

Enhanced Feed Opening Design | Base Técnica: Deep chamber geometry with no dead zone at feed entry | Benefício Operacional: Allows for larger lump size intake and promotes smooth material flow without bridging | Impacto do ROI: Maximizes loader efficiency, reduces need for preblasting or secondary breaking, increasing overall site productivity.

WedgeLocked Jaw Plate System | Base Técnica: Mechanically secured manganese steel plates without complex backing resin | Benefício Operacional: Enables fast reversal or replacement of wear parts during scheduled maintenance windows | Impacto do ROI: Reduz o tempo de inatividade para trocas de revestimento em até 40% compared to bonded systems, aumentando diretamente a disponibilidade da planta.

Ajuste Hidráulico & Limpeza | Base Técnica: Integrated hydraulic system for CSS adjustment and uncrushable material release | Benefício Operacional: Operators can adjust product size or clear blockages safely from ground level in minutes | Impacto do ROI: Eliminates manual shimming labor and prevents costly downtime from tramp metal events.

Volantes de alta inércia | Base Técnica: Precisely calculated rotational mass stored in heavy flywheels | Benefício Operacional: Smoothens power demand peaks and maintains consistent crushing momentum under variable loading | Impacto do ROI: Reduces cyclical stress on drive components and can lower overall energy consumption per ton crushed.

Acionamento direto & VBelt Guarding | Base Técnica: Robust TEFC motor coupled via durable Vbelts with full safety guarding | Benefício Operacional: Provides reliable power transmission with inherent slippage protection; guarding ensures operator safety compliance | Impacto do ROI: Minimizes power transmission losses and reduces maintenance incidents.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Jc5000 Jaw Crusher Solution | Vantagem documentada |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | ~9294% (agendado & não programado) |>96% in field studies| +34% aumento do tempo de produção |
| Use a vida (Placas de mandíbula) Rocha Abrasiva| 120,000 150,000 toneladas| 180,000 220,000 toneladas| +3040% intervalos de serviço mais longos |
| Consumo de Energia por Tonelada| Linha de base 100%| Field data shows ~95%| ~5% reduction in specific energy use |
| Maintenance Time CSS Adjustment/ Clearing| Processo manual (~24 horas)| Sistema hidráulico (<30 minutos)| Até 90% faster adjustment/clearance |

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1500mm x 1300 mm (59" x 51")
Tamanho máximo de alimentação: Até 1300 mm (51")
Requisito de energia: 200 kW / 270 Motor Elétrico HP
Peso Operacional: Aproximadamente 85,000 kg (187,400 libras)
Capacidade de rendimento: Varia de 750 para 1500 mtph depending on feed material and closed side setting (CSS).
Especificações de materiais: Estrutura principal fabricada em aço de alta resistência; Extinguido & tempered alloy steel eccentric shaft; Highgrade manganese steel jaw plates.
Dimensões Físicas (CxLxA): ~4300mm x 3500mm x 4100mm
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C (4°F a +113°F). Kits de vedação contra poeira disponíveis para condições extremas.

6. CENÁRIOS DE APLICAÇÃO

Expansão da Pedreira de Granito | Desafio: Uma grande pedreira necessária para aumentar o rendimento do circuito primário em 25% but was constrained by space for new infrastructure and high wear costs on existing plant. The existing crusher required frequent liner changes causing weekly downtime.| Solução: A single Jc5000 Jaw Crusher replaced two older units due to its higher capacitytofootprint ratio. It was equipped with XtraTough manganese jaw plates.| Resultados: Plant achieved a 28% increase in sustained throughput. Vida útil da peça de desgaste prolongada em 35%, reducing annual consumable costs by an estimated $18,000 USD. The consolidation freed up plant area for downstream upgrades.

Iron Ore Primary Crushing Station Retrofit | Desafio: An aging gyratory crusher at an iron ore site suffered from reliability issues and excessive maintenance hours per month (>80 horas), impacting pellet plant feed.| Solução: Direct retrofit installation of the Jc5000 into the existing primary station footprint. Key features were its hydraulic setting adjustment for quick product size changes between ore types.| Resultados: Maintenance hours related to the primary crusher fell by over 60%. Plant managers reported improved consistency in feed size to SAG mills, contributing to an estimated overall circuit efficiency gain of approximately $50k annually in energy savings alone.

7. CONSIDERAÇÕES COMERCIAIS

The Jc5000 Jaw Crusher is offered as a capital investment in longterm production stability.
Nível de preços do equipamento básico: Includes crusher assembly with standard manganese jaws/motor drives/guards.
Recursos opcionais & Conjuntos: Hydraulic toggle tensioning system; sistema automatizado de lubrificação com graxa; diferentes perfis de placa de mandíbula (por exemplo, corrugated/quarry/super tooth); dust suppression covers; special tool kits.
Pacotes de serviços: Os níveis disponíveis incluem Garantia Básica (12 meses), Planos de suporte estendido (35 anos cobrindo peças/mão de obra), and OnSite Inspection Contracts with OEMtrained technicians.
Opções de financiamento: Flexible capital solutions are available through partners including equipment leasing programs tailored for major capital expenditure cycles typical in mining operations.

8. Perguntas frequentes

Q1 Is the Jc5000 compatible with my existing secondary/tertiary crushing circuit?
Sim. Its hydraulic CSS adjustment allows precise control over discharge product sizing (250mm típico), ensuring optimal feed gradation for most cone crushers or secondary impactors used downstream.

Q2 What is the expected impact on my plant's overall energy consumption?
Field data indicates that due to its efficient direct drive system and highinertia flywheels reducing peak loads on motors plants typically see a net reduction in specific energy use per ton crushed compared to less optimized designs

Q3 How does your OEM support differ from aftermarket parts suppliers?
Our factory R&D ensures that every wear part like jaw plates is metallurgically matched precisely engineered tested alongside original components This guarantees documented performance metrics fit tolerances longevity which generic parts cannot reliably provide

Q4 What are typical lead times for critical spare parts?
For registered service plan holders we operate a dedicated global logistics network with guaranteed dispatch times on critical components like shafts bearings ensuring maximum uptime

Q5 Can we finance this equipment alongside other planned plant upgrades?
Yes Our commercial team structures bundled financing solutions that can include not only the primary crusher but also related conveyors screens structural modifications aligning payment schedules with project cash flow milestones