H1: Engineered for Endurance: The HighYield, LowDowntime Stone Crusher Solution

1. ABERTURA ACIONADA POR PAINPOINT

Managing aggregate production is a constant balance between output targets and operational costs. Para gerentes de fábrica e empreiteiros, the core challenges with a stationary stone crusher machine often center on three critical areas:

Tempo de inatividade não programado: Falhas de rolamento, desgaste de componentes, e quebras inesperadas interrompem toda a sua linha de produção. Industry averages indicate that every hour of crusher downtime can cost between $5,000 e $25,000 em produção perdida, labor inefficiencies, e cronogramas de projetos atrasados.
Saída inconsistente & Qualidade: Fluctuations in feed size or material hardness lead to variable product gradation, producing offspec material that fails to meet contract requirements or requires costly reprocessing.
Altos gastos operacionais: Rising costs for energy consumption, routine maintenance parts (like manganese liners), and dedicated labor for manual adjustments and monitoring directly erode your profit margins.

Are you seeking a stone crusher machine that delivers predictable performance, extends maintenance intervals, and provides a consistent return on your capital investment?

2. VISÃO GERAL DO PRODUTO

Este produto é resistente, primary jaw crusher machine engineered for the continuous reduction of hard, abrasive quarry rock (granito, basalto, cascalho do rio) into primary aggregate. It is designed as the first stage in a multistage crushing and screening plant.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large dump trucks deposit runofquarry material (até 1200 mm) directly into the vibrating grizzly feeder (VGF VGF).
2. Pré-triagem & Esmagamento: The VGF removes natural fines and directs sized material to the bypass chute while oversize rock is fed into the crushing chamber.
3. Compressive Reduction: A robust eccentric shaft drives a moving jaw plate against a fixed jaw plate, aplicando imensa força compressiva para fraturar a rocha.
4. Descarga & Transporte: Crushed material exits through an adjustable discharge opening onto a main product conveyor for transport to secondary processing or stockpiling.

Escopo de aplicação & Limitações:
Escopo: Ideal para britagem primária em pedreiras de alta tonelagem, operações de mineração, and largescale infrastructure projects requiring consistent feed of 5001500 TPH.
Limitações: Not designed for recycling applications with high levels of rebar or tramp metal without extensive prescreening and protection systems. Maximum compressive strength of feed material should not exceed 350 MPa.

3. RECURSOS PRINCIPAIS

Câmara de britagem profunda & Cinemática Otimizada | Base Técnica: Maior ângulo de estreitamento e curso de britagem linear mais longo | Benefício Operacional: Higher volume reduction per cycle, reducing cycle count for same output and promoting slabby product breakage | Impacto do ROI: Até 15% higher throughput capacity compared to conventional chambers of similar intake size.
Hydrostatic Wedge Adjustment System | Base Técnica: Hydraulically actuated wedge mechanism for CSS (Configuração lateral fechada) controlar | Benefício Operacional: Allows remote adjustment of discharge setting in under 2 minutes for product size changes or wear compensation without stopping the crusher | Impacto do ROI: Eliminates manual shim adjustment downtime, economizando uma estimativa 12 hours per adjustment event.
Rolamentos autocompensadores de rolos para serviços pesados & Selos Labirinto | Base Técnica: Oversized bearings rated for high radial and axial loads with multistage sealing | Benefício Operacional: Extended bearing service life under high shock loads; effective exclusion of dust and contaminants | Impacto do ROI: Field data shows bearing service intervals extended by 4060%, reducing part replacement frequency and associated labor.
BoltOn Wear Liners with Lifting Lugs | Base Técnica: Highgrade manganese steel liners secured with captive bolts | Benefício Operacional: Safer and faster liner changes; eliminates backing material headaches; allows for liner profile optimization | Impacto do ROI: Reduces typical liner changeout time by approximately 30%, aumentando a disponibilidade da planta.
Base de motor integrada & Proteção de transmissão por correia | Base Técnica: Unified baseplate for crusher motor and sheaves with full perimeter guarding | Benefício Operacional: Simplified foundation requirements; ensures operator safety; reduces installation time and cost | Impacto do ROI: Cuts installation mechanical costs by an estimated 20% due to preassembled modules.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Our Stone Crusher Machine Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | ~8590% (planejado & paradas não planejadas) |>92% (with scheduled maintenance only) |>5% aumento nas horas produtivas |
| Tonnage per Manganese Wear Life| Varia de acordo com o tipo de rocha; linha de base = 100%| Até 135% of baseline tonnage| Até 35% maior vida útil |
| Consumo Específico de Energia (kWh/tonelada)| Linha de base = 100%| Aproximadamente 92% da linha de base| ~8% reduction in energy cost per tonne |
| Tempo de ajuste CSS (Mecânico)| 6090 minutos (calços manuais)| <2 minutos (hydraulic wedge)| ~97% faster adjustment |

5. ESPECIFICAÇÕES TÉCNICAS

Designação do modelo: JC1400 HeavyDuty Primary Jaw Crusher
Abertura de alimentação: 1400mm x 1200 mm
Tamanho máximo de alimentação: 1200mm comprimento da borda
Faixa de configuração do lado fechado: 150mm 300 mm
Faixa de capacidade: 550 1,450 toneladas por hora (dependente de CSS & material)
Requisitos de energia da unidade: 250 motor elétrico kW (padrão)
Peso do britador (excluindo motor): Aproximadamente 86,000 kg
Principais especificações de materiais:
Quadro Principal: Fabricated steel plate ASTM A36
Placas de mandíbula / Forros: Austenitic Manganese Steel ASTM A128 Gr B3/B4
Eixo Excêntrico: Forged alloy steel EN24 / SAE4340
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Dust suppression system compatible.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito – Sudeste Asiático

Desafio:A major quarry needed to increase primary crushing capacity by over 40% to supply a new highway project but had limited space for new foundations and needed to minimize disruption to existing operations.
Solução:The JC1400 stone crusher machine was selected due to its compact integrated base design allowing it to be positioned on a new reinforced concrete pad adjacent to the existing line. Its hydraulic CSS adjustment allowed quick optimization between ballast and base layer aggregate production.
Resultados:The crusher was commissioned within the planned 8week window. It achieved an average throughput of 1,100 TPH of granite while reporting specific energy consumption 7% below projections.

Basalt Aggregate Production – Middle East

Desafio:The client faced excessive wear costs and unpredictable downtime from their previous primary crusher when processing highly abrasive basalt. Product gradation consistency was also a concern.
Solução:The implementation focused on our machine’s optimized kinematics for better breakage patterns and its heavyduty bearing/sealing package specifically suited for abrasive conditions.
Resultados:Manganese liner life increased by an average of 28%, directly lowering costpertonne wear costs. Crusher availability increased from 87% acabar 93% in the first year of operation due to reduced bearingrelated interventions.

7. CONSIDERAÇÕES COMERCIAIS

Our stone crusher machines are offered in clear pricing tiers based on capacity class:
Nível A (1200 TPH). Transparent quotations include standard factory testing protocols.

Recursos opcionais incluem:
Integrated automatic lubrication systems,
Rock breaker boom systems,
Dust encapsulation kits,
Sensores avançados de monitoramento de condição.

Service packages are available separately:
Garantia Básica,
Extended Protection Plans covering major components,
Annual Inspection Contracts,
Onsite operator training modules.

Financing options can be structured through our partners as capital leases or operating leases with potential buyout options at term end.

8.Perguntas frequentes

1º trimestre:What is the compatibility with my existing secondary cone crushers or screens?
A1:The hydraulic CSS adjustment allows precise control over your primary crushed product size distribution (300milímetros), enabling you to optimize feed for your downstream equipment's specific cavity or screen decks.

2º trimestre:What is the expected impact on my overall plant power draw?
A2.Field data indicates this design can reduce specific energy consumption by approximately 8%. However total plant impact depends on secondary processes; our engineers can model this based on your flow sheet.

3º trimestre:Quais são as condições de pagamento padrão?
A3.Terms are typically 30% down payment upon order confirmation 60% prior to shipment 10% upon completion of commissioning documentation

4º trimestre:What level of technical support is provided during installation?
A4.We provide comprehensive foundation drawings mechanical erection manuals electrical schematics One supervisory engineer is included standard for up 10 days onsite during commissioning

Q5:What is lead time from order placement?
A5.For standard models like JC1400 lead time is typically 16 weeks exworks This includes manufacturing quality control testing painting

Q6:What key spare parts should we stock initially?
A6.We recommend initial stocking one set jaw plates one set toggle plates necessary hydraulic seals This minimizes risk waiting first major wear event

Q7:What training do you provide our operators?
A7.Training covers safe daily operation routine inspection points troubleshooting common alarms proper procedures CSS adjustment liner changeout