Visando gerentes de fábrica, Especialistas em compras, e empreiteiros de engenharia

1. ABERTURA ACIONADA POR PAINPOINT

Managing a crushing and screening operation means contending with persistent challenges that directly erode profitability. Você está enfrentando:
Tempo de inatividade excessivo para manutenção: Mudanças freqüentes de revestimento, falhas de rolamento, and component wear halting production for hours, costing thousands in lost throughput per event.
Gradação inconsistente do produto: Fluctuations in final product size leading to rejected loads, penalidades contratuais, and the need for reprocessing material.
Aumento dos custos operacionais: Uncontrolled spending on energy consumption, peças de reposição, and labor for unplanned repairs.
Configuração de planta rígida: Inability to efficiently adapt your flow to changing feed material or market demands for different aggregate products.
Component Compatibility Issues: Mixing OEM parts from different crusher and screen manufacturers leading to suboptimal performance and accelerated wear.

A questão central é: como você pode alcançar um rendimento previsível, controle mais rígido sobre as especificações do produto, and lower costperton without compromising on durability? The specification of your core equipment is the determining factor.

2. VISÃO GERAL DO PRODUTO: BRITADOR DE MANDÍBULA PRIMÁRIO

A Primary Jaw Crusher is a heavyduty compressiontype crusher designed as the first stage in a mineral processing or aggregate production circuit. It reduces large runofmine or quarryrun rock (typically up to 1meter in size) to a manageable diameter for downstream processing.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large dump trucks or loaders deposit raw material into the vibrating grizzly feeder (VGF VGF) seção, which scalps off fine material bypassing the crusher.
2. Esmagamento por compressão: The VGF directs oversized rock into the crushing chamber where a fixed jaw and a reciprocating moving jaw create a narrowing "V." Material is crushed by the progressive compression cycles as it moves down the chamber.
3. Ajuste de configuração de descarga: The crushed product exits at the bottom opening. The size of this discharge setting is hydraulically or mechanically adjustable to control the top size of the output product.

Escopo de aplicação & Limitações:
Escopo: Ideal for hightonnage primary reduction of hard rock (granito, basalto), materiais abrasivos, e concreto reciclado. Serves as the foundational capacity point for stationary and portable plants.
Limitações: Não é adequado para pegajoso, plastic clays that can chamber; less efficient on lowabrasive, soft limestone compared to an impactor; generates more fines than gyratory crushers at similar settings.

3. RECURSOS PRINCIPAIS

Estrutura soldada para serviço pesado | Base Técnica: Análise de Elementos Finitos (FEA) distribuição de tensão otimizada | Benefício Operacional: Elimina fissuras por fadiga da estrutura sob carregamento cíclico, ensuring longterm structural integrity in 24/7 operações | Impacto do ROI: Eliminates risk of catastrophic frame failure and associated monthslong replacement downtime.

Sistema de ajuste de alternância hidráulica | Base Técnica: Dualacting hydraulic cylinders replace traditional manual toggle plates | Benefício Operacional: Allows remote adjustment of crusher setting in minutes for product size changes and clearing of stall events | Impacto do ROI: Reduz em mais de tempo de inatividade para ajustes 80%, increases plant flexibility and safety.

Aggressive DeepToothed Jaw Dies | Base Técnica: Highstrength manganese steel castings with optimized nip angle and tooth profile | Benefício Operacional: Promotes positive bite on slabby material, reduces slippage, and improves firstpass reduction ratio | Impacto do ROI: Aumenta a capacidade de produção em 515% dependendo do material, reduzindo o custo por tonelada.

Rolamentos autocompensadores de rolos & Selos Labirinto | Base Técnica: Oversized bearings rated for heavy radial and thrust loads with multistage sealing | Benefício Operacional: Lida com picos de carga de produtos não trituráveis; exclui efetivamente poeira e contaminantes do alojamento do rolamento | Impacto do ROI: Prolonga a vida útil do rolamento 3050%, drastically reducing a primary cause of unplanned stoppages.

Base de motor integrada & Protetor de cinto | Base Técnica: Unified fabrication eliminating separate motor mounts; fully enclosed belt guarding | Benefício Operacional: Perfect drive alignment reduces Vbelt wear; compliant guarding improves site safety audit results | Impacto do ROI: Reduces maintenance time on drive components; mitigates regulatory shutdown risks.

4. COMPETITIVE ADVANTANCES

| Métrica de desempenho | Padrão da Indústria | Nossa solução primária de britador de mandíbula | Vantagem |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | 9294% | >96% (documentado) | +24% Tempo de atividade |
| Vida útil do manganês (Granito Abrasivo) | ~450,000 MTON | 520,000 550,000 MTON (dados de campo) | +1522% Vida mais longa |
| Consumo de energia por tonelada triturada| Linha de base (100%)| Optimized chamber geometry reduces draw by ~5%| 5% Custo de energia |
| Hora de ajuste de CSS / Limpeza| 6090 minutos (manual)| <10 minutos (hidráulico)| 85% Adjustment Downtime|
| Classificação de vida útil do rolamento L10| Standard duty cycle rating| Rated for +30% higher load cycles under FEA validation| +30% Theoretical Life |

5. ESPECIFICAÇÕES TÉCNICAS

Referência do modelo: PJ3648
Abertura de alimentação: 36" x 48" (914mm x 1219mm)
Tamanho máximo de alimentação: 32" (813milímetros) caroço
Configuração lateral fechada (CSS) Faixa: 4" 10" (100mm 250 mm)
Faixa de capacidade (@ CSS): 290 790 STPH (263 717 MTPH), depende do tipo de material & crushing curve.
Requisitos de energia da unidade: 150 HP /200 Motor elétrico HP (112kW /149kW).
Peso total (Apenas triturador): ~106,000 lbs (~48,000 kg)
Principais especificações de materiais:
Construção de moldura: Hightensile steel plate ASTM A572 Grade50
Morre a mandíbula: Premium Manganese Steel ASTM A128 Grade BH
Forjamento de eixo: Alloy Steel ASTM A668 Class E
Side Liners/Cheek Plates： Aço resistente à abrasão AR400
Faixa de ambiente operacional: Projetado para temperaturas ambientes de 25°C a +45°C (13°F a +113°F). Sealed components rated for highdust environments.

6. CENÁRIOS DE APLICAÇÃO

Pedreiras de Hard Rock – Produção de Agregados de Granito

Desafio: A granite quarry faced declining profit margins due to high wear part costs on their primary crusher (~400k MTON/jaw set) and excessive energy draw during peak summer loads.
Solução: Implementation of our PJ3648 Primary Jaw Crusher with deeptooth jaw dies design optimized for granite's fracturing characteristics.
Resultados: Wear life extended to an average of $28k MTON per jaw set—a direct $18k cost saving per changeout cycle. Recorded power draw reduced by an average of $7%, translating to approximately $12k annual energy savings at their tonnage rate.

Grande escala C&D Operação de Reciclagem

Desafio: An urban recycling plant experienced frequent jams from rebarreinforced concrete slabs causing fullline stoppages. Manual clearing was dangerous and took over two hours per event.
Solução: Installation of our PJ3042 Primary Jaw Crusher equipped with a hydraulic toggle system capable of reversing tramp iron release function.
Resultados: Jams from uncrushable rebar mats are now cleared remotely in under five minutes using the hydraulic toggle reversal cycle. This change eliminated an average of $40 hours/year of highrisk downtime directly attributed to stall events.

7.CONSIDERAÇÕES COMERCIAIS

Our private label fabrication model provides flexibility tailored to project scale:

Níveis de preços & Estrutura:

1. Pacote de equipamento básico:
Includes crusher assembly with standard manganese jaws,base do motor,belt guards,and lubrication system.Priced as capital expenditure with standard commercial terms.

2.Optional Feature Upgrades:
Hydraulic adjustment system package(highly recommended).
Sistema automatizado de lubrificação com graxa .
Wear monitoring sensor packages(liner thickness,temperatura do rolamento).
Dust suppression spray bar integration kit .

3.Serviço & Support Packages:
Comissionamento & Treinamento de Operadores(no local).
Planned Maintenance Inspections(annual contract).
Wear Parts Kits Subscription(bulk pricing with guaranteed inventory).

Opções de financiamento:
We work with thirdparty equipment finance partners to offer leasetoown structures,tailored rentalpurchase agreements,and standard commercial loans typically ranging from $6$8 years term based on credit approval.This allows preservation of capital lines while deploying upgraded equipment immediately .

8.PERGUNTAS FREQUENTES

Q1.Are your jaw crushers compatible with my existing plant structure/vibrating feeder?
Our engineering team provides interface drawings prior to fabrication.Crushers are built to industrystandard mounting footprints.We can modify discharge heights/support structures if required during quotation .

Q2.What is lead time from order placement?
For standard models like PJ3648 lead time averages $14$18 weeks including fabrication assembly testing paint .Expedited options may be available .

Q3.How does private label branding work?
We fabricate test paint ship equipment under your specified brand name nameplate .All documentation manuals bear your branding .We remain your confidential manufacturing partner .

Q4.What warranty coverage do you provide?
Standard warranty covers workmanship materials against defect for $24 months/4000 operating hours whichever comes first .Extended warranty options available covering major components up five years .

Q5.Can you supply complete crushing spreads screens conveyors ?
Yes.As private label fabricator we provide full circuit design manufacture integration services including primary secondary tertiary crushers screens conveyors transfer structures electrical controls .

Q6.Do you offer performance guarantees?
Yes.We provide guaranteed minimum throughput capacity based your specific feed material sample testing prior order confirmation.Guarantees cover mechanical performance not sitespecific operational outcomes .

Q7.What technical support is available after installation?
Support includes detailed installation manual video conference during commissioning lifetime access technical drawings bill materials unlimited phone email support during business hours field service dispatch available under separate service agreement .