Private Label JC5000 Jaw Crusher Catalog

Your Crushing Operations Are Underperforming—Here’s the Cost

Every hour of unplanned downtime in your primary crushing circuit costs between $5,000 e $15,000 em produção perdida, dependendo da sua tonelagem de alimentação e valor do material. If your current jaw crusher is delivering less than 85% tempo de atividade, you are leaving significant revenue on the table. High wear rates on jaw plates force premature replacements every 3–4 months, adding $12,000–$18,000 annually in consumable costs alone. Inconsistent product gradation creates recirculation loads that reduce overall plant efficiency by 12–18%. Feed blockages from oversized material or sticky ores cause manual intervention, exposing your operators to safety risks and halting production for 30–90 minutes per incident.

Are you absorbing these costs because you believe all jaw crushers perform the same? What if a single equipment upgrade could reduce your cost per ton by 15% while extending wear life by 40%?

Visão geral do produto: The Private Label JC5000 Jaw Crusher

The Private Label JC5000 is a heavyduty primary jaw crusher engineered for continuous operation in hard rock mining, produção agregada, and construction demolition recycling. It processes feed material from 500mm to 1,200mm, reducing it to a consistent 100–250mm product in a single pass.

Fluxo de Trabalho Operacional:
1. Carregamento de feed: Material enters through the 1,200mm x 900mm feed opening via excavator, carregadeira de rodas, or conveyor
2. Compressão Primária: The fixed jaw and moving jaw create a Vshaped crushing chamber; the eccentric shaft drives the pitman to generate compressive forces exceeding 350 MPa
3. Material Fracture: Rock is crushed against the fixed jaw plate through multiple compression cycles as it descends through the chamber
4. Regulamento de Descarga: A configuração do lado fechado (CSS) adjusts from 75mm to 200mm via hydraulic wedges, controlling product size
5. Material Exit: Crushed material discharges onto a belt conveyor or into a surge bin for secondary processing

Escopo de aplicação: Rock pesado (granito, basalto, quartzito), rock meio duro (calcário, dolomite), concreto reciclado e asfalto, mining ores (cobre, ouro, ferro)

Limitações: Not suitable for clayrich materials exceeding 15% teor de umidade; requires 6–8 weeks lead time for custom jaw plate profiles; tamanho máximo de alimentação limitado a 80% da largura da abertura de alimentação

Recursos principais

Geometria otimizada da câmara de britagem | Base Técnica: Análise de elementos finitos (FEA) optimized toggle plate angle and chamber profile | Benefício Operacional: Reduz a carga recirculante em 22% compared to straight chamber designs | Impacto do ROI: Lowers energy consumption by 8–12 kWh per 100 toneladas processadas

Sistema de ajuste hidráulico CSS | Base Técnica: Twin hydraulic cylinders with position sensors adjust the closed side setting in under 3 minutos | Benefício Operacional: Elimina ajustes manuais de calços, reduzindo o tempo de troca em 85% | Impacto do ROI: Recovers 40–60 minutes of production time per setting change

HighStrength Manganese Jaw Plates | Base Técnica: 18% manganese alloy with chromium carbide overlay on wear zones | Benefício Operacional: Achieves 14,000–18,000 tons of wear life in granite applications | Impacto do ROI: Reduces annual consumable costs by $4,500–$7,200 per crusher

Advanced Flywheel Design | Base Técnica: Dual flywheels with 8,500 kg·m² moment of inertia | Benefício Operacional: Maintains consistent crushing force during peak load cycles, reducing motor current spikes by 30% | Impacto do ROI: Extends motor and Vbelt life by 18–24 months

Sistema de lubrificação automática | Base Técnica: Programmable grease injection to all bearing points at 15minute intervals | Benefício Operacional: Elimina a lubrificação manual, reducing maintenance labor by 3 horas por semana | Impacto do ROI: Prevents bearing failures that cost $8,000–$12,000 per replacement event

Reversible Jaw Plate Design | Base Técnica: Symmetrical plate geometry allows 180degree rotation | Benefício Operacional: Doubles usable wear life before replacement | Impacto do ROI: Saves $2,800–$4,500 per set of jaw plates

Alívio integrado de ferro vagabundo | Base Técnica: Hydraulic relief cylinder with 350bar pressure threshold | Benefício Operacional: Passa por objetos inquebráveis (brocas, dentes de balde) sem danos estruturais | Impacto do ROI: Avoids $15,000–$25,000 in frame repair costs per incident

Vantagens Competitivas

| Métrica de desempenho | Padrão da Indústria (200–300 HP Jaw Crusher) | Solução JC5000 de marca própria | Vantagem (% Melhoria) |
|||||
| Taxa de transferência (toneladas/hora) | 250–350 toneladas por hora | 320–420 tph | 20–28% higher |
| Tempo de atividade (média anual) | 82–88% | 93–97% | 10–15% de melhoria |
| Cost per ton (peças de desgaste) | $0.18–$0,25 | $0.12–$0.16 | 33–36% reduction |
| Tempo de ajuste de CSS | 15–25 minutes | 2–3 minutos | 85–88% faster |
| Jaw plate life (granito) | 9,000–12,000 tons | 14,000–18,000 tons | 40–55% longer |
| Motor power consumption | 0.8–1.2 kWh/ton | 0.6–0.9 kWh/ton | 20–25% lower |
| Feed opening utilization | 65–75% | 80–90% | 15–20% de melhoria |

Especificações Técnicas

| Parâmetro | Especificação |
|||
| Abertura de alimentação | 1,200 milímetro x 900 milímetros (48" x 36") |
| Tamanho máximo de alimentação | 950 milímetros (37") |
| Faixa CSS | 75–200mm (3"–8") |
| Capacidade de rendimento | 320–420 tph (based on CSS and material density) |
| Potência do motor | 250–300 kW (335–400 HP) |
| Velocidade do motor | 1,500 RPM (50 hertz) / 1,800 RPM (60 hertz) |
| Velocidade do eixo excêntrico | 220–260 RPM |
| Flywheel Weight (cada) | 4,250 kg |
| Peso total (somente britador) | 38,500 kg |
| Material da Estrutura Principal | EM 10025 Aço estrutural S355JR, 40espessura mm |
| Material da placa da mandíbula | 18% Mn, 2% Cr, 1.2% C (ASTM A128 Grau C) |
| Tipo de rolamento | Rolamentos autocompensadores de rolos, SKF 23244 CC/W33 |
| Lubrication Capacity | 8 liters grease reservoir |
| Faixa de temperatura operacional | 20°C a +50°C (4°F a +122°F) |
| Dimensões (C x L x A) | 3,800 milímetro x 2,400 milímetro x 3,100 milímetros |
| Configuração de envio | 2 x 20foot containers (crusher and motor separately) |

Cenários de aplicação

Pedreira de rocha dura, Noruega | Desafio: Processamento 800,000 tons/year of granite with 18% silica content caused jaw plate wearout every 2,800 horas, exigindo 32 hours of downtime per replacement | Solução: Private Label JC5000 with 18% manganese jaw plates and reversible design | Resultados: Vida útil da placa de mandíbula estendida para 4,100 horas (46% melhoria); annual downtime reduced from 128 horas para 72 horas; cost per ton decreased from $0.22 para $0.14

Reciclagem de Demolição de Construção, Alemanha | Desafio: Processing mixed demolition waste with rebar and concrete required frequent tramp iron events, causing structural damage to previous crusher every 6 meses | Solução: JC5000 with integrated hydraulic tramp iron relief and automatic reset | Resultados: Zero structural damage over 18 meses de operação; tramp iron passage time reduced from 45 minutos para 4 minutos; plant uptime increased from 79% para 94%

Mina de cobre, Chile | Desafio: Primary crushing at 4,200 meters altitude with 35°C temperature swings caused lubrication failures in standard crushers | Solução: JC5000 with highaltitude lubrication package and thermal expansion compensation | Resultados: Bearing failures eliminated over 24month period; rendimento mantido em 380 tph despite altitude; maintenance costs reduced by $18,000 anualmente

Considerações Comerciais

Níveis de preços de equipamentos:

• Pacote Padrão ($285,000–$315,000): Crusher assembly, 250 motor kW, Acionamento por correia em V, standard manganese jaw plates, kit de ferramentas básicas
• Pacote Aprimorado ($345,000–$385,000): Includes hydraulic CSS system, lubrificação automática, controle remoto sem fio, spare jaw plate set
• Pacote Premium ($425,000–$475,000): Full automation package with PLC control, monitoramento de vibração, oil analysis sensors, 3year wear parts warranty

Recursos opcionais:

• Custom jaw plate profiles for specific feed materials: $4,500–$8,000 per set
• Highaltitude modification kit (above 3,000m): $12,500
• Sistema de supressão de poeira (water spray nozzles): $6,800
• Motor soft starter or VFD: $9,500–$ 18.000
• Pacote de telemetria de monitoramento remoto: $7,200

Pacotes de serviços:

• Contrato anual de manutenção: $18,000/ano (inclui 2 inspeções, suporte técnico prioritário)
• Fullservice agreement: $42,000/ano (inclui toda a manutenção programada, peças de desgaste a custo, 48hour response guarantee)
• Training package: $6,500 (3day onsite operator and maintenance training for up to 8 pessoal)

Opções de financiamento:

• Locação de equipamentos: 36–Prazos de 60 meses com $1 aquisição, starting at $6,800/month
• Pagamento diferido: 90day payment deferral with 0% interest for qualified buyers
• Programa de negociação: Até $45,000 credit for qualifying used jaw crushers (200 HP or larger)

Perguntas frequentes

1. What is the lead time for a Private Label JC5000?
Standard production lead time is 8–10 weeks from order confirmation. Entrega rápida (6 semanas) está disponível com um 5% sobretaxa. Custom jaw plate configurations add 2–3 weeks.

2. Can the JC5000 process recycled concrete with rebar?
Sim. The hydraulic tramp iron relief system passes rebar up to 25mm diameter without damage. For larger rebar concentrations, we recommend a prescreening grizzly to remove oversized steel.

3. What is the expected annual maintenance cost?
Baseado em 2,000 operating hours per year in hard rock applications, annual maintenance costs average $22,000–$28,000, including jaw plate replacement (um conjunto), bearing lubrication, and minor repairs.

4. Does the JC5000 require a concrete foundation?
Sim. A reinforced concrete foundation with minimum dimensions of 5m x 4m x 1.5m is required, with anchor bolts embedded to our provided template. Foundation design support is included with the purchase.

5. Qual cobertura de garantia é fornecida?
Coberturas de garantia padrão 24 meses ou 6,000 horário de funcionamento, o que ocorrer primeiro. Coverage includes structural frame, eixo excêntrico, e rolamentos. Peças de desgaste (placas de mandíbula, placa de alternância) estão excluídos. Opções de garantia estendida estão disponíveis.

6. Can the JC5000 be integrated with existing plant control systems?
Sim. The PLCbased control system supports Modbus RTU, Profibus, e protocolos Ethernet/IP. Integration documentation and technical support are provided at no additional cost.

7. Qual é o nível de ruído durante a operação?
No 1 distância do metro, the JC5000 operates at 85–92 dB(UM) sob carga total. We recommend hearing protection for operators within 15 metros. Optional acoustic enclosures reduce noise to 78 dB(UM) no 1 medidor.