1. ABERTURA ACIONADA POR PAINPOINT

Are you managing recurring costs and operational bottlenecks in your size reduction process? Distribuição inconsistente de tamanho de partícula, frequência excessiva de substituição de peças de desgaste, e o tempo de inatividade não planejado para manutenção não são apenas inconvenientes — eles impactam diretamente seus resultados financeiros. Quando seu moinho de martelos apresenta desempenho inferior, você enfrenta um aumento no consumo de energia por tonelada processada, custos mais elevados de estoque de peças de reposição, and potential downstream processing delays.

Is inconsistent feed material causing unpredictable output fineness and affecting your final product quality?
Você está substituindo martelos, telas, and liners too often, struggling with both parts costs and labor hours?
Does mill vibration or bearing failure lead to catastrophic unplanned shutdowns, interrompendo toda a sua linha de produção?
Are you sacrificing throughput capacity because your current equipment cannot handle material variability or requires constant operator adjustment?

These challenges underscore the need for a hammer mill engineered not just to crush, but to deliver operational reliability and predictable costperton performance.

2. VISÃO GERAL DO PRODUTO: ODM HeavyDuty Hammer Mill

Este ODM (Fabricante de design original) hammer mill is a robust industrial impact crusher designed for highvolume reduction of mediumhard to hard materials. It is engineered for continuous operation in demanding mineral processing, produção agregada, e aplicações de fresamento industrial.

Fluxo de Trabalho Operacional:
1. Alimentação controlada: O material é introduzido através de um sistema de alimentação regulado (por exemplo, alimentador vibratório, transportador de correia) na câmara de moagem.
2. Redução de Impacto: Martelos giratórios rápidos (montado em um rotor resistente) transmitir energia cinética, shattering material against the breaker plates and chamber walls.
3. Classificação de tamanho: Sized particles exit through a perforated screen grate; material de tamanho grande permanece na câmara para redução adicional.
4. Descarga: Processed material is conveyed away for the next stage of operation.

Escopo de aplicação: Ideal para calcário, gesso, carvão, agregados, materiais de construção reciclados, e certos minérios metálicos. Não recomendado para materiais altamente abrasivos (por exemplo, areia de sílica) sem configurações específicas de liga, ou para pegajoso, highmoisture content feeds that may cause screen clogging.

3. RECURSOS PRINCIPAIS

Sistema de rotor reversível | Base Técnica: O design simétrico do rotor permite a rotação final | Benefício Operacional: Duplica a vida útil das bordas do martelo antes da substituição; enables quick change of impact direction to combat asymmetric wear | Impacto do ROI: Reduces annual hammer inventory costs by up to 50% e estende os principais intervalos de manutenção.

Revestimentos de desgaste segmentados | Base Técnica: Bolton liner sections made from alloy steel or AR plate | Benefício Operacional: Individual sections can be replaced during scheduled maintenance without dismantling the entire housing; minimiza o tempo de inatividade | Impacto do ROI: Reduz o tempo de inatividade para substituição do revestimento em aproximadamente 70% compared to weldedplate designs.

Balanceamento Dinâmico & HeavyDuty Bearings | Base Técnica: Factory rotor balancing to ISO G6.3 standard paired with oversized spherical roller bearings | Benefício Operacional: Eliminates destructive vibration at operational speeds; ensures smooth running under variable load conditions | Impacto do ROI: Prolonga a vida útil do rolamento em mais 40%, preventing costly secondary damage from vibrationinduced failure.

Tela de mudança rápida & Hammer System | Base Técnica: Hydraulic or mechanical assist systems for accessing the grinding chamber | Benefício Operacional: Enifies changeover of screen grate sizes and hammer sets in hours instead of shifts | Impacto do ROI: Aumenta a flexibilidade e o tempo de atividade da planta; allows rapid adaptation to different product specifications with minimal lost production.

Dual Drive Pulley Configuration | Base Técnica: Multiple Vbelt sheaves distributing power from dual motor drives | Benefício Operacional: Provides redundant power transmission; reduces stress on individual belts and motors; allows for easier tensioning | Impacto do ROI: Lowers risk of complete drive failure; improves overall transmission efficiency by 35%, reducing energy waste.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | This ODM Hammer Mill Solution | Vantagem documentada |
| : | : | : | : |
| Toneladas por hora / kWh (for ~25mm limestone) | 8 10 TPH/kWh | 11 13 TPH/kWh | +2030% Eficiência Energética |
| Vida útil do martelo (under defined conditions) | 400 600 horário de funcionamento | 800 1,200 horário de funcionamento (reversible) | +100% Vida útil |
| Tempo de troca de tela (for major size change) | 8 12 horas-homem | 3 5 horas-homem (with assist)| 60% Tempo de inatividade |
| Nível de ruído em 1 Medidor (sob carga total)| >105 dB(UM) | <98 dB(UM) (with sealed housing)| Improved OSHA Compliance |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: dependente do modelo, de 50 TPH acima 300 TPH in aggregate applications.
Requisitos de energia: De 160 kW até 630 kW (250 HP – 850 HP), configured for either direct drive or belt drive.
Diâmetro do rotor & Largura: Options from Φ1000mm x L1200mm to Φ2000mm x L3000mm.
Especificações de materiais: Carcaça construída em chapa de aço carbono resistente (>20mm thick). Standard hammers are forged alloy steel; optional DuroMax™ or manganese steel alloys available. Rotor shaft is hightensile forged steel.
Tamanho máximo de alimentação: Up to ≤500mm edge length depending on model.
Faixa de tamanho do produto: Adjustable from ≤5mm to ≤50mm based on screen selection.
Faixa de temperatura operacional: Ambient to +60°C (+140°F); bearing housings include provisions for cooling if required.
Contenção de poeira: Fully sealed housing with multiple shaft seals; flanged connections for dust extraction systems.

6. CENÁRIOS DE APLICAÇÃO

Planta de Produção de Agregados – Processamento de Calcário

Desafio: A quarry’s existing hammer mill produced excessive fines (<3milímetros), wasting marketable product fractions while struggling with high vibration that led to quarterly bearing failures.
Solução: Implementation of a midrange ODM hammer mill with a dynamically balanced rotor and optimized screen grate geometry.
Resultados: Fines generation reduced by ~18%, increasing saleable product yield. Bearing service life extended to over 18 meses de operação contínua. Overall plant availability increased by an estimated ~5%.

Mineral Processing Pilot Plant – Versatility Requirement

Desafio: An engineering contractor required flexible crushing equipment for pilot testing various ore types without lengthy reconfiguration periods between tests.
Solução: Installation of an ODM hammer mill featuring the quickchange screen/hammer system and reversible rotor.
Resultados: Changeover time between different ore test batches reduced from one full day to under four hours. The reversible rotor feature allowed them to process a highly abrasive sample without immediate parts replacement after initial wear was observed.

7. CONSIDERAÇÕES COMERCIAIS

Pricing tiers are structured according to capacity rating and construction material grade:
Série de serviço padrão: For consistent feed materials like coal or softer aggregates. Offers core reliability at an entry capital cost.
Série para serviços pesados: The most common specification for general quarrying and mineral processing, featuring all core features listed above.
SevereDuty Series: Includes upgraded alloys throughout wear components (forros,martelos), specialized shaft seals,and premium bearings for highly abrasive or corrosive feeds.

Recursos opcionais incluem:
Sistemas de lubrificação automatizados
Sensores de monitoramento de vibração com integração PLC
Explosionproof construction
Custom mobile skid mounting

Service packages range from basic commissioning support up through comprehensive annual maintenance contracts with guaranteed parts availability windows.Financing options including leasetoown programs are available through partner institutions,making capital expenditure manageable within operational budgets.

8.Perguntas frequentes

1º trimestre:What level of moisture in feed material can this hammer mill handle?
A1:Practical field data suggests optimal operation with feed moisture below ~15%.For higher moisture content,fines may agglomerate,causing screen blinding.A heated chamber option is available for specific highmoisture applications like certain clays.

2º trimestre:What is the typical lead time on critical wear parts like hammers or screens?
A2:Due our ODM manufacturing model we maintain substantial raw stock.For standard alloys lead times average two weeks.Guaranteed expedited shipping options exist within our service contracts ensuring minimal operational disruption

Q3.How does this equipment integrate with our existing feeding conveying system?
A3:The mills are designed with standardized inlet outlet flange dimensions adaptable via transition pieces.Engineering drawings are provided upfront allowing your team contractors plan integration seamlessly into existing layouts

Q4.What kind foundation required installation ?
A4:A reinforced concrete foundation mass approximately three times machine weight recommended dampen operational vibrations.Detailed foundation drawings anchor bolt templates included delivery documentation

Q5.Are performance guarantees offered ?
A5 Yes we provide guaranteed throughput capacity particle size distribution curves based controlled test runs agreed representative sample material prior contract finalization

Q6.Can you supply matching ancillary equipment feeders conveyors dust collection ?
A6 As an ODM manufacturer we act as single point contact source coordinate supply all necessary ancillary equipment through vetted partners simplifying procurement logistics ensuring system compatibility