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, os principais desafios na britagem primária geralmente incluem:
Desgaste Excessivo & Custos de manutenção: Frequent replacement of manganese wear parts due to improper crushing dynamics, leading to thousands in unbudgeted parts and labor.
Tempo de inatividade não programado: Unplanned stoppages for clearing blockages or addressing mechanical failures, halting your entire downstream processing line.
Gradação inconsistente do produto: Fluctuations in feed material hardness or size causing offspec product, resulting in pile recrushing and wasted energy.
Alto Consumo de Energia por Tonelada: Inefficient crushing chambers and drive systems that draw maximum power without delivering proportional throughput.
Rigidez para variações de alimentação: Equipment that cannot effectively handle occasional oversize or slightly wet material without risking significant operational disruption.

A questão central passa a ser: como você pode proteger robusto, highcapacity primary crushing performance without the premium price tag and achieve a faster return on investment?

2. VISÃO GERAL DO PRODUTO

The Premium Stone Crusher Machine represents a highefficiency, heavyduty jaw crusher engineered for primary reduction of hard rock, granito, basalto, e concreto reciclado. Its design prioritizes mechanical simplicity and durability to deliver reliable firststage crushing.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Material de alimentação grande (até dimensões de entrada especificadas) é depositado no alimentador vibratório do urso pardo (opcional), que contorna multas para otimizar o carregamento da câmara.
2. Ciclo de esmagamento: Material entra nas profundezas, nonchoking crushing chamber where a steep nip angle and aggressive linear stroke apply compressive force against a fixed jaw plate.
3. Descarga: O material triturado sai pelo ponto de descarga inferior, with product size determined by the closedside setting (CSS) of the crusher, readily adjustable via hydraulic or mechanical shim systems.

Escopo de aplicação: Ideal para pedreiras estacionárias, operações de mineração em grande escala, e locais de grandes projetos de infraestrutura que exigem, hightonnage production of base materials (por exemplo, 06”, 08” aggregate).

Principais limitações: Não projetado para moagem ultrafina ou como britador terciário. O tamanho e a capacidade máximos de alimentação estão sujeitos às especificações do modelo. Performance with highly abrasive but noncompressive materials (por exemplo, certos arenitos) may accelerate wear compared to compressive rock.

3. RECURSOS PRINCIPAIS

Construção de estrutura para serviços pesados | Base Técnica: Análise de Elementos Finitos (FEA) distribuição de tensão otimizada | Benefício Operacional: Elimina fissuras por fadiga da estrutura sob carregamento cíclico; fornece plataforma estável para todos os componentes | Impacto do ROI: Vida estrutural estendida além 15+ anos sob operação normal, eliminando a substituição prematura de capital.

Geometria otimizada da câmara de britagem | Base Técnica: Cinemática modelada por computador e design de ângulo de estreitamento | Benefício Operacional: Promove a trituração interpartículas para melhorar a taxa de redução; reduz o produto lascado; minimizes direct wear on jaw dies | Impacto do ROI: Até 15% higher throughput per kWh consumed based on field data; more uniform wear extends jaw plate life by an estimated 20%.

Alternar Hidráulico & Sistema de ajuste | Base Técnica: Cilindros hidráulicos de dupla ação substituem placas articuladas mecânicas tradicionais | Benefício Operacional: Permite segurança, rapid clearing of blockages without manual intervention; allows remote adjustment of CSS for product control | Impacto do ROI: Reduces downtime from tramp metal events from hours to minutes; allows quick adaptation to changing product specs without stopping feed.

Volantes de alta inércia & Eixo excêntrico robusto | Base Técnica: Precisely calculated rotational mass to sustain momentum through the crushing stroke | Benefício Operacional: Suaviza os picos de demanda de energia, reducing cyclic load on the drive motor; ensures consistent crushing force even under variable loading | Impacto do ROI: Protects motor from burnout, lowers demand charges on power supply; enables use of standard highefficiency motors.

EasyAccess Maintenance Design | Base Técnica: Modular component layout with dedicated service platforms (opcional) | Benefício Operacional: All routine inspection points (toggle system, caixas de rolamento) are accessible without major disassembly | Impacto do ROI: Reduces planned maintenance service time by approximately 30%, reduzindo os custos de mão de obra e aumentando a disponibilidade da planta.

Acabamento de componentes resistentes à corrosão | Base Técnica: Industrialgrade protective coatings on internal frames and critical fasteners | Benefício Operacional: Protects against moisture and abrasive dust ingress in harsh environments | Impacto do ROI: Preserves asset value and resale potential; prevents corrosionrelated seizure of adjustment mechanisms.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Industry Standard for Comparable Jaw Crushers | Premium Stone Crusher Machine Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade)| ~92% (incluindo. planejado & paradas não planejadas) |>95% based on telemetry data from installed units| +3.3% Production Time |
| Toneladas por MWh| 180 220 tons/MWh for hard granite| 235 250 tons/MWh demonstrated in field trials| +10% Média. Eficiência Energética |
| Vida útil da peça (Placas de mandíbula)| Altamente variável; média. 120k tons in abrasive rock| Consistent achievement of 140k+ tons in same material| +16% Média. Vida útil |
| Tempo de ajuste CSS| 12 horas (mechanical shim system)| <15 minutos (sistema hidráulico padrão)| ~85% Faster Adjustment |
| Emissão de Ruído a 1m| Tipicamente 108112 dB(UM)| Gabinetes projetados & damping achieve ≤105 dB(UM)| ~37 dB(UM) Redução |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: De 350 MTPH para 1,200 MTPH, depending on feed material density and crushability index.
Abertura de alimentação: Sizes from 900mm x 600mm up to 1,300mm x 1,000mm.
Requisito de energia: Driven by standard TEFC electric motors ranging from 75 kW para 160 kW. Motor starter not included.
Especificações de materiais: Estrutura de aço fabricada de alta resistência (ASTM A36). Highgrade cast steel swing jaw body. Matrizes de mandíbula de aço manganês (14% /18% opcional). Forged alloy steel eccentric shaft with precisionmachined bearings.
Dimensões Físicas (Modelo típico): Aprox.. Comprimento: ~7m; Largura: ~3m; Altura: ~3m (excluindo alimentador & transportador de descarga).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Dust seals rated for IP66 protection against particulate ingress.

_(MTPH = Metric Tons Per Hour)_

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Desafio: A southeastern US quarry needed to increase primary capacity by 40% but faced space constraints and a limited capital budget for foundational work.
Solução: Implementation of a single highcapacity Premium Stone Crusher Machine with a deepchamber configuration replaced two older units.
Resultados: Achieved required throughput increase within existing footprint. Energy consumption per ton dropped by an estimated $0.$12/ton due to higher efficiency plantwide availability increased by $4$%.

Major Highway Infrastructure Contractor

Desafio: Onsite crushing of excavated rock was plagued by frequent uncrushable material (rebar remnants), causing daily downtime for manual clearing on their previous crusher.
Solução: Deployment of the Premium Stone Crusher Machine equipped with the automatic hydraulic toggle release system.
Resultados: Blockage clearance events were resolved remotely in under two minutes versus an average of $90$ minutes previously Project completed ahead schedule saving an estimated three weeks of idle equipment labor costs

Aggregate Producer Processing Variable Feed

Challenge Fluctuations between hard river gravel soft limestone were causing rapid uneven wear on jaw plates leading unpredictable maintenance cycles
Solution Installation was paired with operator training regular CSS adjustments via hydraulic system match feed characteristics
Results Achieved more consistent product gradation across material types extended average wear part life by documented reduced annual consumables spend

7 CONSIDERAÇÕES COMERCIAIS

Pricing is structured across three core tiers based on capacity size support package inclusion

Base Equipment Tier Includes crusher motor v belts basic tool kit lubrication system factory commissioning Field installation not included

Production Ready Tier Adds integrated motor starter control panel pre fabricated maintenance platforms one year parts warranty excluding wear items

Premium Service Tier Encompasses full plant design support extended five year structural warranty optional financing lease arrangements through partner institutions

Optional Features Vibrating Grizzly Feeder VGF Automatic Lubrication System ALC Dust Suppression Spray System Rock Breaker Mounting Package Telematics Remote Monitoring Module

Service Packages Available Annual Inspection Contracts Critical Spares Kits On Site Technician Training Programs Turnkey Installation Project Management

8 Perguntas frequentes

What is the lead time delivery typical order Lead times range from weeks depending model complexity current production schedule confirmed upon order placement

Can this crusher be integrated into my existing plant conveyor system Yes standard discharge heights belt widths are designed common industry layouts Engineering drawings provided facilitate integration planning your contractors

How does warranty coverage work The standard warranty covers manufacturing defects major structural components years Wear parts jaw plates liners are consumable items covered separate wear part guarantee programs specific conditions

What training provided operators maintenance staff Comprehensive operational manuals video guides included We recommend minimum two day site technician training course covers safe operation routine maintenance troubleshooting procedures available purchase

Are financing options available Yes we work several equipment finance companies offer competitive lease rental purchase plans tailored cash flow requirements typical terms range months