Targeted Quarry Ballast Crushing Solutions: Engineered for Throughput, Shaped for Specification

1. PAINPOINT DRIVEN OPENING

Producing consistent, specificationgrade railway ballast is a critical yet demanding operation. Inefficient crushing processes directly impact your bottom line and project timelines. Are you managing these persistent challenges?
High Abrasion Costs & Unscheduled Downtime: The constant grinding of hard, abrasive rock rapidly wears crusher components, leading to frequent stoppages for liner changes and maintenance, disrupting your entire production schedule.
Poor Product Shape & Fines Generation: Cubical particles are essential for track stability. Flaky or elongated aggregates fail specification checks, while excess fines represent wasted tonnage and potential environmental handling issues.
Inconsistent Throughput and Bottlenecks: Can your primary crushing stage keep up with feed, or does it create a bottleneck that idles your loading and secondary processing equipment?
Rising Operational Expenditure: Are you facing escalating costs from energy consumption, manual adjustment labor, and the high frequency of wear part replacement?

The right primary crushing equipment is not just a purchase; it's a strategic decision that defines your plant's productivity and profitability for years.

2. PRODUCT OVERVIEW: HEAVYDUTY JAW CRUSHER FOR BALLAST PRODUCTION

This heavyduty jaw crusher is engineered as the primary workhorse for highvolume quarry ballast production. It is designed to accept large feed material from the quarry face and reduce it to a consistent, manageable size for secondary crushing and screening.

Operational Workflow:
1. Feed Intake: Large dump trucks deposit blasted rock (typically up to 1000mm) directly into the crusher’s vibrating grizzly feeder (VGF), which removes natural fines and bypasses subsize material.
2. Primary Reduction: The VGF directs oversize material into the robust crushing chamber, where a steep nip angle and aggressive crushing action apply immense compressive force to fracture the rock.
3. Discharge & Conveyance: Crushed material is discharged at a preset closedside setting (CSS) onto the main product conveyor for transport to subsequent processing stages.

Application Scope & Limitations:
Scope: Ideal for primary reduction of hard, abrasive igneous rock (granite, basalt) and dense limestone to produce railway ballast, subbase, and other construction aggregates.
Limitations: Not suitable for sticky or claybound materials without prescreening. Maximum feed size is determined by model selection; extremely slabby feed may require prior breaking.

3. CORE FEATURES

Modular Jaw Die Design | Technical Basis: Boltin, reversible wear sections | Operational Benefit: Reduces liner change downtime by up to 50%. Operators can replace sections individually or rotate them for even wear utilization. | ROI Impact: Lower labor costs per maintenance event and increased crusher availability directly boost annual production tonnage.

Hydraulic Toggle Adjustment System | Technical Basis: Dualacting hydraulic cylinders replace traditional mechanical toggle plates | Operational Benefit: Enables remote CSS adjustment in minutes under load for precise product size control. Provides automatic clearing of chamber blockages. | ROI Impact: Eliminates manual shim adjustments, minimizes unplanned stoppages from tramp metal or bridging, ensuring consistent spec output.

QuarryGrade Steel Frame & Spherical Roller Bearings | Technical Basis: Fabricated steel plate housing with oversized bearing seats | Operational Benefit: Provides exceptional structural integrity to withstand decades of highcycle fatigue loading from hard rock crushing. | ROI Impact: Extended service life of core crusher structure reduces longterm capital replacement costs.

Optimized Crushing Chamber Geometry | Technical Basis: Computermodeled kinematics and nip angle design | Operational Benefit: Promotes interparticle crushing action in the lower chamber zone, enhancing cubical product shape while reducing direct wear on jaw dies. | ROI Impact: Higher yield of premium, specificationcompliant ballast stone with less waste fines generation.

Integrated Motor Base & Belt Drive | Technical Basis: Unified base frame supporting crusher, drive motor(s), and sheaves | Operational Benefit: Simplifies installation alignment reduces site preparation work ensures optimal Vbelt tensioning during operation.| ROI Impact Faster plant commissioning lower installation contractor fees reduced risk of belt slippagerelated inefficiencies

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Mechanical Toggle Jaw) | Our Jaw Crusher Solution | Advantage |
| : | : | : | : |
| CSS Adjustment Time (Under Load) | 46 hours (manual shim) | < 10 minutes (hydraulic) | ~95% faster |
| Wear Part Life (Mn18/22 Liners in Granite) | ~400k MTON | ~550k MTON (Field data shows typical improvement)| ~37% longer |
| Total Energy Consumption per Tonne Crushed| Baseline 100%| Approximately 92%| ~8% reduction |
| Planned Maintenance Downtime (Annual)| ~120 hours| ~70 hours| ~42% less |

5. TECHNICAL SPECIFICATIONS

Feed Opening: 1300mm x 1000mm
Maximum Feed Size: 850mm edge length
Closed Side Setting Range: 150mm 250mm (optimized for ballast)
Capacity Range (@ CSS 200mm): Up to 750 MTPH (varies with feed material)
Drive Power Requirement: 200 kW electric motor
Total Weight (Crusher + Motor Base): ~62 metric tons
Key Material Specifications: Highstrength fabricated steel frame; Martensitic steel jaw dies standard; Optional ceramic composite liners for feed hopper.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with standard lubrication systems.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project – National Rail Network Supplier

Challenge: A major supplier needed to increase ballast output by 40% but was constrained by their existing primary crusher’s downtime for liner changes and mechanical adjustments.
Solution: Implementation of our heavyduty jaw crusher with modular jaw dies and hydraulic toggle system as the new primary stage.
Results: Plant achieved target throughput increase within six months. Liner change downtime reduced from two shifts to one shift per event. Product shape consistency improved, reducing rejections at final screening.

Basalt Aggregate Producer – Port Infrastructure Development

Challenge: Producing highspecification armor stone and railway ballast from extremely abrasive basalt led to unsustainable wear part costs in their conventional primary crushers.
Solution: Installation of our jaw crusher configured specifically for high abrasion resistance.
Results: Wear life on stationary jaw plates increased by an average of 30%. Combined with easier maintenance access operational cost per tonne was reduced by an estimated 22%

7 COMMERCIAL CONSIDERATIONS

Our quarry ballast crushing equipment is offered through a transparent tiered pricing structure:
Base Equipment Tier Includes core crusher drive motor base VGF feeder skid walkways ladders standard instrumentation
Optional Features Tier Includes automated grease lubrication system dust suppression spray system extended wear part packages advanced motor starters remote monitoring hardware interface
Service Packages Choose from three levels Annual Inspection & Advisory Full Maintenance Contract Turnkey Wear Part Management including scheduled changeouts

We offer several commercial pathways including direct capital purchase longterm lease agreements or tailored financing plans structured through our industrial partners designed to align payment schedules with your project cash flow

FAQ

What type of secondary/tertiary crusher works best downstream from this unit?
For optimal railway ballast shaping this jaw crusher is typically paired with a cone crusher in closed circuit configuration Field data indicates this combination most effectively controls particle shape while managing overall plant yield

How does this equipment handle uncrushable material like tramp metal?
The hydraulic toggle system incorporates an automatic release function When an uncrushable object enters the chamber pressure builds triggering the hydraulic cylinders to open wider allowing the object to pass preventing catastrophic damage

What are typical delivery lead times?
For standard models lead time ranges between months following order confirmation Custom configurations may require additional engineering time We provide detailed project planning schedules upon request

Can we retrofit features like hydraulic adjustment onto our existing older jaw crushers?
No The hydraulic toggle system requires specific frame geometry casting design Retrofitting existing mechanical toggle machines is not feasible due fundamental structural differences

What training do you provide operators maintenance staff?
We include comprehensive onsite commissioning training covering safe operation routine inspection procedures basic troubleshooting A detailed operations maintenance manual specific provided digitally in advance