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, the core challenges in primary crushing often stem from the initial reduction stage. Os pontos problemáticos comuns incluem:

Alto custo por tonelada: Inefficient crushing chambers and excessive wear part consumption directly increase your cost per ton of produced aggregate.
Tempo de inatividade não programado: Premature component failure or the need for frequent, complex adjustments halts your entire processing line, custando milhares por hora em perda de produção.
Manuseio inconsistente de feeds: Ponte, segregação, and difficulty processing variable feed sizes (from fines to large slabs) lead to chokeups, rendimento reduzido, and increased equipment stress.
Trabalho de manutenção excessivo: Designs that require frequent, manual greasing or lengthy procedures for wear part inspection and replacement tie up skilled personnel on reactive tasks.
Limitações de configuração rígida: Fixed plant designs that cannot adapt to changing feed material characteristics or final product specifications limit your operational flexibility and market responsiveness.

A questão central é: como você pode estabelecer um sistema mais confiável, eficiente, and profitable primary crushing foundation? The solution begins with selecting the right primary stone crusher plant.

2. VISÃO GERAL DO PRODUTO

This product line comprises stationary and semistationary primary jaw crusher plants engineered for the first reduction stage of hard rock (granito, basalto) e agregados abrasivos. The plant integrates a robust jaw crusher with a heavyduty vibrating grizzly feeder (VGF VGF) and necessary onboard conveyors onto a single chassis.

Fluxo de Trabalho Operacional:
1. Alimentar & Escalpelamento: Runofquarry material is dumped into the vibrating grizzly feeder (VGF VGF), which simultaneously feeds the crusher at a controlled rate and scalps out undersize material to bypass the crusher, improving overall efficiency.
2. Redução Primária: The core jaw crusher utilizes compressive force to break large stones against a fixed jaw plate. A steep nip angle and optimized kinematics ensure aggressive bite and high reduction ratios.
3. Descarga & Transporte: Crushed material is discharged at a specified CSS (Configuração lateral fechada) onto an integral product conveyor for transport to the next stage in your processing circuit.

Escopo de aplicação & Limitações:
Escopo: Ideal for primary crushing in quarrying, mineração, e projetos de construção em grande escala. Suited for highabrasion materials where durability is critical.
Limitações: Not designed as a finished product solution; output requires secondary/tertiary crushing for most specification aggregates. Maximum feed size is determined by crusher model opening. Requer estável, prepared ground for setup.

3. RECURSOS PRINCIPAIS

Câmara de britagem profunda & Cinemática Agressiva | Base Técnica: Steep nip angle design combined with high inertia flywheels | Benefício Operacional: Enables effective processing of larger feed blocks with fewer choke points, increasing usable capacity | Impacto do ROI: Reduces need for preblasting or secondary breaking, lowering drilling/blasting costs by an estimated 1015%.

Alimentador Grizzly Vibratório para Serviço Pesado (VGF VGF) | Base Técnica: Unitized vibrator assembly with adjustable grizzly bar section | Benefício Operacional: Provides consistent material flow to the crusher cavity while removing fines, preventing overload and reducing jaw plate wear on softer material | Impacto do ROI: Melhora o rendimento geral da planta ao 812% by optimizing crusher load and can extend jaw liner life.

Ajuste Hidráulico & Sistema de compensação | Base Técnica: Integrated hydraulic rams for toggle tensioning and chamber clearing | Benefício Operacional: Allows operators to adjust CSS quickly for product size changes and safely clear blockages without manual intervention | Impacto do ROI: Reduz em mais de tempo de inatividade para ajustes/limpeza 70%, translating to hundreds of recovered production hours annually.

Projeto de peça de desgaste BoltOn & Plataformas de acesso | Base Técnica: Modular jaw dies secured with standard bolts; full perimeter access platforms | Benefício Operacional: Permite mais segurança, faster liner changes during scheduled maintenance windows without specialized lifting equipment inside the chamber | Impacto do ROI: Reduz o tempo de troca do revestimento em até 50%, reduzindo os custos de mão de obra e aumentando a disponibilidade da planta.

Lubrificante Centralizado & Sistema de controle CLP | Base Técnica: Automated grease lubrication to key bearings; programmable logic controller with safety interlocks | Benefício Operacional: Ensures critical bearings receive correct lubrication without operator reliance; provides monitoring of key functions like power draw and temperature | Impacto do ROI: Evita falhas catastróficas nos rolamentos; dados de campo mostram um 30% reduction in lubricationrelated component issues.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução primária para britador de mandíbula | Vantagem documentada |
| : | : | : | : |
| Toneladas por hora (TPH) Eficiência (at same CSS) | Linha de base 100% (Model Dependent) | Até 115120% of comparable class models | +1520% melhoria |
| Jaw Liner Life (em granito abrasivo) ~500600 hrs MTBF| ~500600 hrs MTBF| 650750 hrs MTBF| +2025% vida útil mais longa |
| Total Energy Consumption por tonelada triturada| Linha de base 100% kWh/tonelada| Aproximadamente 9295 kWh/tonelada| 58% menor custo de energia |
| Tempo médio para reparar (MTTR) for liner change| ~24 manhours| ~1214 manhours| ~45% faster serviceability |
| MTBF = Mean Time Between Failures |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 150 TPH acima 900 TPH final output capacity.
Abertura de alimentação do britador: Sizes from 900mm x 600mm up to 1500mm x 1300mm.
Requisitos de energia: Potência total instalada da planta de 150 kW para 400 kW dependendo da configuração. Alimentação padrão em 400V/50Hz ou personalizável.
Especificações de materiais: Fabricado em aço de alta resistência (S355JR+). Jaw plates available in multiple manganese steel grades (14%,18%,22%) tailored to abrasiveness.
Dimensões Físicas (Típico): Comprimento aprox.. ~15m – ~22m; Largura aprox.. ~3m – ~4m; Altura aprox.. ~4m – ~5m.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. As conexões do sistema de supressão de poeira são padrão.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Desafio: An existing quarry needed to increase primary output by 40% but faced space constraints limiting major layout changes. Their legacy plant required excessive maintenance time.
Solução: Implementation of a highcapacity primary jaw crusher plant with an integrated prescalper on a compact chassis footprint.
Resultados: Achieved the targeted throughput increase within the existing feed area. Reduced monthly scheduled maintenance hours by onethird due to improved access features.

Basalt Aggregate Production for Highway Construction

Desafio: Highly abrasive basalt was causing premature wear on competitor equipment (650 hrs average), allowing accurate maintenance scheduling that eliminated unplanned stoppages during peak construction periods.

7. CONSIDERAÇÕES COMERCIAIS

Our private label stone crusher plants are offered under three main tiers:

1. Nível de produção padrão: Highreliability core configuration ideal for consistent feed materials—includes basic PLC controls, manual CSS adjustment option, centralized lube system (Hydraulic adjustment optional).
2. Nível de alta disponibilidade: Recommended for demanding multishift operations—adds full hydraulic adjustment/clearing system, sensores automatizados de monitoramento de peças de desgaste, extended warranty on major castings (Opcional).
3. Custom Project Tier Engineeredtoorder solutions incorporating specific feeder lengths discharge heights conveyor configurations or specialized wear materials

Recursos opcionais incluem:
Onboard diesel/electric dualpower module
Dust encapsulation systems
Advanced telemetry packages

Service Packages range from basic commissioning support through comprehensive annual maintenance contracts including guaranteed parts delivery schedules

Financing options are available including straight purchase capital lease or productionbased rentalto own agreements structured through our financial partners

Perguntas frequentes

Q What is required at my site prior installation?
A A level stable compacted base capable of supporting total dynamic load plus adequate space around unit safe operation service access Provision threephase electrical power connection point within specified cable length

Q How does this integrate with my existing secondary tertiary circuit?
A Our engineering team will review your current flow sheet specifications ensure proper matching capacity product sizing We provide standard discharge conveyor heights adapt most common downstream equipment

P Qual prazo de entrega típico?
A For Standard Tier configurations lead time typically weeks following order confirmation Custom configurations require detailed engineering review will have projectspecific timeline provided quotation

Q As peças sobressalentes estão prontamente disponíveis?
A Yes As manufacturer maintain comprehensive inventory critical wearing structural parts We commit hour response time quote requests expedited shipping options minimize potential downtime events

P Você pode fornecer garantias de desempenho?
A Yes performance metrics based agreedupon material testing sample Guarantees regarding minimum throughput maximum power consumption wear rates established contractually prior purchase