1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de produção agregadas? Para gerentes de fábrica e empreiteiros de engenharia, the core challenges in material reduction often stem from inefficient primary crushing. Os pontos problemáticos comuns incluem:
Tempo de inatividade excessivo para manutenção: Frequent liner changes and unplanned repairs on your primary crusher halt your entire processing line, custando milhares por hora em perda de produção.
Redução inconsistente do tamanho da alimentação: Variable feed material causes chokefeeding or erratic performance, leading to downstream bottlenecks in your secondary and tertiary circuits.
Altos custos operacionais: Soaring energy consumption per ton of processed material and premature wear part failure directly impact your bottomline profitability.
Limited Flexibility & Escalabilidade: A fixed crushing solution cannot adapt to changing feed materials or increased production targets without significant capital reinvestment.

Is your primary crushing station the bottleneck in your operation? O que seria um 1520% reduction in costperton mean for your annual budget? The solution lies in specifying a highperformance, reliable primary crushing station engineered for maximum uptime and efficiency.

2. VISÃO GERAL DO PRODUTO: PRIMARY CRUSHING STATION

A Primary Crushing Station is a complete, semifixed or modular system designed for the first stage of size reduction in quarrying, mineração, and largescale construction applications. Its function is to accept runofmine or blasted feed material (up to 1000mm+) and reduce it to a conveyable size for transport to downstream processing.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Dump trucks deposit material into a robust vibrating grizzly feeder (VGF VGF).
2. Redução Primária: The VGF scalps fines and directs oversize material into a highcapacity jaw crusher or gyratory crusher for initial compression breaking.
3. Manuseio de Materiais: Crushed product is discharged onto a main conveyor belt system for transport to the next stage of processing.

Escopo de aplicação: Ideal for hightonnage hard rock (granito, basalto), minérios abrasivos, and recycled concrete operations requiring throughput from 500 acabar 2,500 tph.

Limitações: Not suitable as a standalone solution where final product specification is required; must be integrated with secondary/tertiary crushing and screening circuits. Site requires adequate space for setup and feed access.

3. RECURSOS PRINCIPAIS

Patented Quarry Jaw Design | Base Técnica: Cinemática otimizada & reinforced chamber geometry | Benefício Operacional: Achieves higher reduction ratios with lower wear rates, minimizing frequency of liner changes | Impacto do ROI: Reduces wear part inventory costs by an estimated 18% and increases crusher availability

HeavyDuty Modular Base Frame | Base Técnica: Pré-projetado, bolttogether substructure with integral walkways | Benefício Operacional: Enables faster site installation and future relocation without heavy fabrication work | Impacto do ROI: Cuts installation time by up to 40%, accelerating timetoproduction

Intelligent Variable Speed Feeder Control | Base Técnica: PLCdriven VGF with loadsensing technology | Benefício Operacional: Automatically regulates feed rate to prevent crusher overload (choke) or underutilization (starve) | Impacto do ROI: Optimizes power draw, improving energy efficiency by up to 12% and maximizing throughput

Sistema integrado de supressão de poeira | Base Técnica: Strategically placed nozzle arrays with solenoid control tied to crusher operation | Benefício Operacional: Actively suppresses dust at key transfer points only when needed, conserving water | Impacto do ROI: Ensures regulatory compliance while reducing water consumption by approximately 30%

Lubrificação Centralizada & Lube Station | Base Técnica: Singlepoint connection for automated lubrication of all major bearings | Benefício Operacional: Permite segurança, routine maintenance from one location in under 15 minutos | Impacto do ROI: Enhances bearing life by ensuring consistent lubrication, preventing costly failures

HighStrength Discharge Conveyor | Base Técnica: Channel frame design with impact bars at loading zone | Benefício Operacional: Withstands continuous heavy loads and direct impact from crushed discharge | Impacto do ROI: Reduces belt damage and spillage, lowering conveyor maintenance costs

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Our Primary Crushing Station Solution | Vantagem documentada |
| : | : | : | : |
| Disponibilidade (Tempo de execução agendado) | 8892% | 95%+| +47% Melhoria |
| Custo por tonelada (Peças de desgaste) | Linha de base (100%)| 85%| 15% Redução |
| Instalação & Tempo de comissionamento| 810 Semanas| 56 Semanas| ~40% Faster Deployment |
| Consumo de energia (kWh/tonelada)| Varia de acordo com o tipo de rocha| Até 12% Mais baixo| Verified by field telemetry |
| Tempo médio entre falhas (MTBF)| ~1,200 hours| >1,600 horas| +33% Reliability Increase |

5. ESPECIFICAÇÕES TÉCNICAS

Tipo de britador: HeavyDuty Single Toggle Jaw Crusher
Abertura de alimentação: 1,400mm x 1,200mm (55" x 47")
Tamanho máximo de alimentação: 1,000milímetros (39")
Configuração lateral fechada (CSS) Faixa: 150mm 300 mm (6" 12")
Faixa de capacidade: Até 900 1,200 tph (depende da densidade do material & CSS)
Impulsione a potência: Tier IV Final / Stage V compliant dieselelectric or direct electric drive options; 200 kW main crusher motor.
Structural Fabrication: Hightensile steel plate with abrasionresistant liners at critical wear points.
Station Footprint (C x L): Approximately 28m x 8m (92' x 26').
Faixa de temperatura operacional: 25°C a +45°C (13°F a +113°F) with appropriate fluid specifications.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Challenge A granite producer needed to increase plant throughput by 35% but was constrained by an aging primary crusher causing 10 hours of weekly unplanned downtime.
Solution Implementation of our modular Primary Crushing Station with the patented jaw design and intelligent feeder control.
Results Station commissioned in 5 semanas. Atingiu um rendimento sustentado de 950 tph with availability exceeding 96%. Costperton reduced by 18%, paying back the investment in under 14 meses.

LargeScale Infrastructure Development

Challenge A civil engineering contractor required a temporary highvolume crushing solution for processing excavated basalt on a major highway project, with strict dust control regulations.
Solution Deployment of a mobileprimarycrusherconfigured station with integrated dust suppression and quickrelocation capability.
Results The station processed over 2 million tons of material onsite across three different project phases. Dust emissions remained within compliance limits without slowing production, eliminating offsite hauling costs.

7. CONSIDERAÇÕES COMERCIAIS

Our Primary Crushing Stations are offered in three capabilitybased tiers:
Essential Tier: Highreliability core system ideal for consistent feed materials. Base pricing structured around required throughput capacity.
Nível de desempenho: Includes advanced features like intelligent feeder control, automated lubrication,and enhanced dust suppression for operations targeting optimal costperton.
Elite Tier: Fully customized stations with premium components,surge capacity design,and predictive maintenance telemetry integration for megaprojects.

Optional features include onboard power generation sets,magnet systems for tramp metal removal,and heated operator stations.Service packages range from basic commissioning support to comprehensive Planned Maintenance Agreements covering parts,trabalho,e inspeções programadas. As opções de financiamento incluem contratos de arrendamento mercantil,aluguel sob medida para estruturas próprias,e financiamento baseado em projetos através de parceiros credenciados.

8. Perguntas frequentes

Q1 Is this Primary Crushing Station compatible with my existing secondary plant?
A Yes.The discharge conveyor speed heightand load capacity are engineered during specificationto match your downstream receiving hopper or screen feed conveyor ensuring seamless integration.

Q2 What is the expected operational impact during liner changes?
A Our jaw design features hydraulic setting adjustmentand reversible liners.Field data shows liner changeout can be completed typically within one standard shift minimizing production loss comparedto older designs requiring longer downtime

Q3 Are there financing options available that alignwith our project cash flow?
A Yes.We offer several commercial structures including operating leases that preserve capitaland milestonebased payment plans tiedto commissioningand performance verification

Q4 How does the intelligent feeder control handle highly variable feed material?
A The PLC system monitors crusher power drawin realtime automatically slowingor speedingthe feeder tomaintain optimal chamber loading This protects the crusherfrom tramp metal eventsand mitigates the effectsof size variation

Q5 What trainingis providedfor our maintenance crew?
A Comprehensive trainingis included covering daily inspections routine maintenance proceduresand wear part replacement protocols Documentation includes detailed manualsand troubleshooting guides