1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? Para gerentes de fábrica e empreiteiros, the reliability of primary crushing is nonnegotiable. Os desafios comuns com máquinas trituradoras de pedra abaixo do ideal incluem:
Tempo de inatividade não programado: Falhas mecânicas frequentes e trocas demoradas de componentes param toda a sua linha de processamento, custando milhares por hora em perda de produção.
Alto consumo de peças de desgaste: Premature failure of jaws, forros, and blow bars due to inferior metallurgy or design leads to excessive spare parts inventory and labor costs.
Saída inconsistente & Formato do produto: Unreliable crushing chambers produce poor particle size distribution, negatively impacting downstream screening efficiency and final product quality.
Consumo excessivo de energia: Inefficient drive systems and crushing kinematics result in higherthannecessary power consumption per ton of material processed.
Flexibilidade de configuração limitada: Fixed designs that cannot adapt to changing feed materials or final product specifications force operational compromises.

E se o seu britador primário pudesse oferecer um desempenho previsível, menor custo por tonelada, and adapt to your specific site requirements? The solution lies in selecting a purposeengineered OEM stone crusher machine built for affordability through total cost of ownership, not just initial price.

2. VISÃO GERAL DO PRODUTO

O [Fabricante/Série Modelo] é um robusto, stationary primary jaw crusher engineered for highvolume reduction of hard rock, granito, basalto, e cascalho do rio. Its design prioritizes structural integrity and operational simplicity for longterm reliability in demanding quarry and mining applications.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Material de alimentação grande (up to specified feed opening) é carregado no alimentador vibratório do urso pardo (opcional), que contorna multas para otimizar o carregamento da câmara.
2. Ação Esmagadora: Material entra nas profundezas, symmetrical crushing chamber where a highinertia flywheel and optimized nip angle facilitate powerful compressive crushing.
3. Descarga & Regulamento: Crushed material exits at the bottom with a consistent discharge gap setting, adjustable via a hydraulic or mechanical shim system to control final product size.

Escopo de aplicação: Ideal for primary crushing stations in aggregate production, operações de mineração, e reciclagem de resíduos de construção em grande escala. Suitable for feed sizes up to 1200mm and compressive strengths up to 320 MPa.

Limitações: Não projetado para aplicações de reciclagem abrasiva sem opções específicas de revestimento. Requires a stable concrete foundation and appropriate upstream feeding equipment for optimal performance.

3. RECURSOS PRINCIPAIS

ESTRUTURA SOLDADA PESADA | Base Técnica: Análise de Elementos Finitos (FEA) construção otimizada em chapa de aço | Benefício Operacional: Eliminates stress cracking under cyclical loads, ensures alignment integrity for all internal components | Impacto do ROI: Prolonga a vida estrutural além 15+ anos sob operação normal, eliminating risk of catastrophic frame failure.

ADVANCED CRUSHING CHAMBER DESIGN | Base Técnica: Computermodeled kinematics with an aggressive nip angle and deep symmetric profile | Benefício Operacional: Promotes interparticle crushing for higher reduction ratios and more uniform cubical product shape | Impacto do ROI: Increases yield of inspec product by an estimated 812%, reduzindo a carga de recirculação e melhorando a eficiência a jusante.

SISTEMA DE AJUSTE DE ALTERNATIVA HIDRÁULICA | Base Técnica: Integrated hydraulic cylinder for safe adjustment of the closedside setting (CSS) | Benefício Operacional: Allows operators to change product size or clear blockages in minutes without manual shims | Impacto do ROI: Reduz em mais o tempo de inatividade para alterações de CSS 70%, translating to hundreds of additional production hours annually.

PREMIUM COMPONENT SELECTION | Base Técnica: Rolamentos autocompensadores de rolos com lubrificação automatizada; eixo excêntrico de liga de aço forjado | Benefício Operacional: Handles peak loads with high radial and axial strength; ensures smooth operation with minimal heat generation | Impacto do ROI: Bearing service life increased by approximately 40% em comparação com designs padrão, lowering maintenance frequency and cost.

LOWMAINTENANCE LINER PROFILE | Base Técnica: Reversible/interchangeable jaw dies manufactured from Mn18% or Mn22% steel alloys | Benefício Operacional: Maximiza a utilização do material de desgaste; simplifies replacement procedure requiring fewer service hours | Impacto do ROI: Reduces liner inventory costs by up to 30% through reversibility; cuts labor time per changeout by half.

VBELT DRIVE & GUARD SYSTEM| Base Técnica: Highcapacity multiple Vbelt transmission with OSHAcompliant guards | Benefício Operacional: Efficient power transmission with inherent shock absorption; ensures operator safety during operation| Impacto do ROI: Lower installation cost compared to direct drives; easy field replacement of standard belt components minimizes parts lead time dependency.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Linha de base padrão da indústria | Our OEM Stone Crusher Solution | Vantagem documentada |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | ~8588% (incluindo manutenção programada) |> 92% availability over a 5year period| +57% melhoria |
| Custo por tonelada (Peças de desgaste) | Based on standard Mn14/18 liners | Optimized Mn18/22 liners with reversible design | Até 20% reduction in wear cost per tonne crushed |
| Consumo de energia | Standard AC motor drive | Motores IE3 de alta eficiência & optimized flywheel mass | Estimado 58% menor kWh/tonelada |
| Definir o tempo de ajuste | Sistema de calço manual (48 horas) | Integrated hydraulic adjustment system (90% ajuste mais rápido |

5. ESPECIFICAÇÕES TÉCNICAS

Designação do modelo: [por exemplo, JC160]
Abertura de alimentação: 1600mm x 1200 mm
Tamanho máximo de alimentação: ≤1000mm
Configuração lateral fechada (CSS) Faixa: 150mm 300 mm
Faixa de capacidade (@ dado CSS): 450 950 toneladas por hora
Capacity varies based on feed material characteristics.
Requisitos de energia da unidade: 200 kW (Motor elétrico de alta eficiência IE3)
Peso total (Apenas triturador): Aproximadamente 62,000 kg
Principais especificações de materiais:
Fabricação de molduras: Highstrength S355J2 steel plate
Jaw Dies Standard Material: Manganese Steel ASTM A128 Gr E1 / Mn18%
Material do eixo excêntrico: Forged Alloy Steel EN24 / SAE4340
Bearings Type & Size Spherical Roller Bearings; 240x500x160mm
Faixa de temperatura do ambiente operacional: 20°C a +45°C (com lubrificantes apropriados)

6. CENÁRIOS DE APLICAÇÃO

Expansão da Pedreira de Granito, Southeast Asia Challenge:

A large aggregate producer needed to double primary capacity but was constrained by limited plant footprint and high local maintenance labor costs. Their existing crushers required frequent liner changes causing significant downtime.

Solução:

Installation of two JC160 OEM jaw crushers configured with hydraulic toggle systems and automated lubrication packages. The deepchamber design accommodated the variable granite hardness without bridging.

Resultados:

A disponibilidade da planta aumentou de ~82% para mais 91%. Liner changeout time reduced from two shifts (~16 horas) per machine to under one shift (<8 horas). The project achieved its capacity target within the existing footprint layout.

Basalt Aggregate Production for Rail Ballast Challenge:

A contractor on a major rail infrastructure project faced strict particle shape requirements (high cubicity index) for ballast material. Their existing primary crusher produced excessive flaky material, overloading the secondary cone crushers and failing spec consistently.

Solução:

Replacement of the primary unit with our OEM stone crusher machine featuring the optimized chamber geometry specifically tuned for abrasive basalt applications.

Resultados:

Postcrushing cubicity improved by an average of 15%. Recirculating load to secondary stage decreased by approximately 25%, allowing the entire circuit to meet daily tonnage specifications reliably. Wear life on secondary crusher liners saw a corresponding increase due to better feed shape.

7. CONSIDERAÇÕES COMERCIAIS

Our commercial model is structured around providing clear value at each investment level:

Níveis de preços
1. Base Equipment Package Includes core jaw crusher assembly motor drives guards basic tool kit
2 Production Optimization Package Adds integrated hydraulic toggle system automated centralised grease lubrication system wear monitoring sensors
3 Turnkey Skid Package Crusher premounted on heavyduty fabricated steel skid complete with feeders motor starters walkways

Optional Features Fieldproven upgrades such as different liner metallurgies dust suppression spray systems special guarding configurations extended warranty coverage

Service Packages Choose from annual inspection plans comprehensive maintenance contracts or payasyougo technical support All include access OEM spare parts network

Financing Options We work with accredited partners offer equipment leasing operating leases projectbased financing terms typically range months years designed match cash flow projects

8 Perguntas frequentes

Q What are minimum foundation requirements this stone crusher machine?
A Detailed foundation drawings specifying concrete volume grade reinforcement are provided as part technical documentation General rule thumb concrete mass should be times mass crusher assembly ensure stability dynamic loads

Q How does handle wet sticky feed materials?
A While designed primarily hard rock modifications available such different liner profiles optional rock box prevent packing chamber However extremely claybound materials may require prescreening washing upstream optimal performance

Q What typical lead time delivery after order confirmation?
A For standard configurations lead time typically weeks exworks Customized skidmounted solutions may require weeks depending scope engineering required

Q Are wear parts interchangeable other brands similar size?
A No Our wear parts are engineered specifically our chamber kinematics geometry Using nonOEM parts will void warranty compromise performance metrics throughput product shape we guarantee

Q Do you provide commissioning supervision operator training?
A Yes Basic commissioning supervision included all purchases We strongly recommend onsite operator maintenance training sessions which can be quoted separately ensure correct longterm operation

Q Can this machine be integrated into existing automated control system PLC/
A The crushers standard equipped necessary instrumentation pressure switches temperature sensors easily interface modern plant PLC via analog digital I points Documentation provided integration