1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? In primary crushing, the challenges are consistent: consumo excessivo de peças de desgaste gerando alto custo, unplanned stoppages for maintenance, and throughput bottlenecks that delay downstream processes. Considere sua operação atual. How often do you face premature jaw plate failure? What is the true cost of a full shift lost to liner changes or adjustment issues? Are vibration and instability limiting your crusher’s performance on harder feed materials? These operational hurdles directly impact your bottom line through increased spare parts inventory, custos trabalhistas, e perda de produção. O Wholesale JC5000 Jaw Crusher is engineered to address these specific, quantifiable pain points.

2. VISÃO GERAL DO PRODUTO

O Wholesale JC5000 Jaw Crusher é um serviço pesado, singletoggle primary crushing machine designed for highcapacity processing of hard rock, minério, e concreto de demolição em configurações de instalações estacionárias. Seu fluxo de trabalho operacional foi desenvolvido para oferecer confiabilidade: (1) Feed material enters the deep crushing chamber with aggressive nip angle, (2) A robust eccentric shaft and largediameter flywheels drive a powerful crushing stroke, (3) The fixed jaw die remains stationary while the moving jaw exerts high pressure to fracture material, (4) Crushed product discharges via gravity at the bottom under controlled settings, (5) Hydraulic assist systems enable rapid adjustment and clearing. Its application scope includes primary reduction in mining, produção agregada em grande escala, e processamento mineral industrial. It is not suited for ultrafine grinding or as a secondary/tertiary unit without specific circuit design considerations.

3. RECURSOS PRINCIPAIS

Construção de estrutura para serviços pesados | Base Técnica: Modular, nonwelded stressrelieved steel castings | Benefício Operacional: Eliminates stress cracking under cyclical loads; provides longterm structural integrity in 24/7 operações | Impacto do ROI: Reduz o risco de falha catastrófica da estrutura, estendendo a vida útil além 15+ anos com manutenção adequada.

Geometria otimizada da câmara de britagem | Base Técnica: Deep symmetrical chamber with steep nip angle (26°) | Benefício Operacional: Promotes particleonparticle crushing for reduced liner wear; increases capacity by preventing choke at the feed opening | Impacto do ROI: Melhora o rendimento por 812% over conventional designs with similar feed size.

Alternar Hidráulico & Sistema de ajuste | Base Técnica: Cilindros hidráulicos de dupla ação substituem placas articuladas mecânicas | Benefício Operacional: Enables remote clearing of blockages and quick setting adjustments in minutes versus hours; fornece proteção contra sobrecarga | Impacto do ROI: Cuts downtime for chamber clearing by up to 80%, maximizing equipment utilization.

Conjunto de rolamento de alto desempenho | Base Técnica: Spherical roller bearings on eccentric shaft with larger bore diameter | Benefício Operacional: Suporta capacidades de carga mais altas e suporta cargas de choque de materiais não trituráveis; runs cooler at sustained high power | Impacto do ROI: Extends bearing service intervals by approximately 40%, lowering lubrication and replacement costs.

Replaceable BoltIn Cheek Plates | Base Técnica: Thick steel plates secured with captive bolts on crusher sides | Benefício Operacional: Protege a estrutura do desgaste; allows for easier replacement than welded designs during maintenance cycles | Impacto do ROI: Simplifies liner maintenance schedule, reducing labor hours per changeout event.

Durable Jaw Die Design | Base Técnica: Reversible manganese steel dies with multiple tooth profiles available | Benefício Operacional: Maximiza a utilização do material de desgaste; allows selection of optimal profile for abrasion or impact dominance in feed material | Impacto do ROI: Increases tons crushed per die set by 1525%, reduzindo diretamente as métricas de costperton.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Classe comparável) | Desempenho documentado da solução JC5000 | Vantagem (% Melhoria) |
| : | : | : | : |
| Use a vida (Rocha Abrasiva)| 450,000 550,000 tons per jaw die set| 600,000 700,000 toneladas por conjunto| +18% para +27% |
| Tempo de inatividade para ajuste de CSS| Manual shims/plates (~46 horas)| Sistema hidráulico (~45 minutos)| 88% |
| Eficiência energética (kWh/tonelada)| Varia de acordo com o tipo de rocha; linha de base = 100%| Dados de campo mostram redução consistente| 5% para 8% |
| Peak Throughput Capacity| Rated at ~750 mtph (granito duro)| Sustained rates of ~800820 mtph achieved| +7% para +9% |
| Tempo médio entre falhas (Principal)| ~8.000 horas de operação| Excede 10,000 horas em casos documentados| +25% |

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1500mm x 1200 mm (59" x 47")
Tamanho máximo de alimentação: ~1000 mm de comprimento da borda (subject to material characteristics)
Configuração lateral fechada (CSS) Faixa: 150mm 300 mm
Faixa de capacidade: Até 830 toneladas métricas por hora (dependente de CSS & material)
Requisitos de energia da unidade: 200 kW / 270 Motor elétrico HP
Peso total: Aproximadamente 62,000 kg
Principais especificações de materiais: Highstrength cast steel frame; Eixo excêntrico forjado; Matrizes de mandíbula de aço manganês & placas de bochecha.
Ambiente Operacional: Projetado para temperaturas ambientes de 20°C a +45°C. Padrão de vedação contra poeira; optional systems available for extreme conditions.

6. CENÁRIOS DE APLICAÇÃO

Desafio da Estação Primária de Pedreira de Granito:

A large aggregate producer faced frequent downtime due to premature wear on cheek plates and lengthy CSS adjustments using manual methods.
Solução:
Implementation of two JC5000 Jaw Crushers as primary units.
Resultados:
Wear part life extended by an average of 22%. Adjustment time reduced from over half a shift to under one hour per crusher. Annual plant availability increased by an estimated ~300 hours.

Iron Ore Processing Plant Challenge:

High throughput requirements were hampered by chokefeed incidents causing significant blockage clearance downtime.
Solução:
Integration of the JC5000 with its hydraulic toggle system into a new greenfield processing line.
Resultados:
Blockages are cleared remotely in under ten minutes without personnel entering the crushing chamber. Plant achieved designed throughput of >750 mtph within one week of commissioning.

7. CONSIDERAÇÕES COMERCIAIS

The Wholesale JC5000 Jaw Crusher is offered through tiered pricing aligned with configuration:

Nível de equipamento básico: Includes crusher assembly with standard motor mounts/vbelts and basic tool kit.
Operational Ready Tier: Base unit plus integrated hydraulic power pack & sistema de lubrificação.
Camada Integrada de Planta: Full package including motor starters/variable frequency drive skidded platform walkways access ladders

Optional features include automated grease lubrication systems multiple jaw die tooth profiles special alloy liners for extreme abrasion dust suppression ring packages

Service packages range from annual inspection plans to comprehensive multiyear performance agreements covering parts labor scheduled maintenance Financing options including leasetoown capital equipment loans are available through certified partners

8. Perguntas frequentes

Q1 Is the JC5000 compatible with my existing primary crusher foundation?
A1 Detailed dimensional drawings are provided Engineering review is recommended but it is designed as a replacement for many crushers in its class requiring foundation verification rather than complete redesign

Q2 Qual é o impacto operacional esperado no rendimento geral da minha planta?
A2 Field data shows most plants see a net capacity increase due to higher availability However final impact depends on downstream process capabilities A circuit analysis is advised

Q3 How does the pricing structure work for wholesale or multipleunit orders?
A3 Significant volume discounts apply for orders of two or more units Contact our sales engineering team for a projectspecific quotation

Q4 What training is provided for our maintenance crew on the hydraulic system?
A4 Comprehensive operation and maintenance manuals are supplied along with optional onsite training sessions conducted during commissioning

Q5 Are wear parts readily available globally?
A5 A standardized inventory of all critical wear parts including jaw dies cheek plates bearings is maintained within our global distribution network ensuring lead times typically under two weeks