Impact Crushers Contract Manufacturer
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع دير سان توهان جي مجموعي پيداوار جي مارجن کي ختم ڪري رهيا آهن? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, the secondary crushing stage is a critical bottleneck where inefficiencies translate directly to lost revenue. Common challenges with conventional impact crushers include:
اضافي لباس حصو خرچ: Premature failure of blow bars and wear liners due to inconsistent feed material or suboptimal impact dynamics, بار بار جي اڳواڻي, متبادل لاء قيمتي بندش.
سار سنڀال لاءِ اڻ رٿيل وقت: Difficult access to the crushing chamber and complex rotor service requirements extend routine maintenance from hours to days, idling your entire processing line.
Product Gradation Inconsistency: Uncontrolled particle velocity and poor chamber geometry result in an unpredictable product curve, forcing downstream adjustments and compromising final spec compliance.
اعلي توانائي واپرائڻ في ٽون: Inefficient transfer of energy from rotor to material, often exacerbated by outdated drive systems, inflates your most controllable operating expense.
What if your impact crushing operation could deliver higher throughput with lower costperton, while maintaining scheduled availability above 95%? The solution lies in a precisionengineered impact crusher designed not just to crush, but to optimize your entire circuit's financial performance.
2. پيداوار جو جائزو: HEAVYDUTY SECONDARY IMPACT CRUSHER
This equipment is a horizontal shaft impact (ايڇ ايس آءِ) crusher engineered for highvolume reduction of limestone, ٻيهر استعمال ٿيل ڪنڪريٽ, اسفالٽ, and other mediumhard aggregates in stationary plant configurations. ان جي آپريشنل ڪم فلو جي وضاحت ڪئي وئي آهي ڪنٽرول طرفان, highinertia impact:
1. ڪنٽرول ٿيل فيڊ: Material is directed by a adjustable feed chute onto the rotating assembly.
2. تيز رفتار اثر: Feed material is struck by massive manganesealloy blow bars mounted on a solid steel rotor, ڀڃڻ جي شروعات.
3. Accelerated Projection: Broken material is propelled into robust adjustable aprons or grinding path for secondary reduction.
4. ڪنٽرول ٿيل خارج ٿيڻ: Sized product exits through hydraulically adjustable discharge opening, ensuring consistent gradation.
ايپليڪيشن جو دائرو: Ideal for secondary crushing duties following a primary jaw crusher, and for primary crushing of nonabrasive materials like limestone. Effective for recycling applications (ڪنڪريٽ, اسفالٽ).
اهم حدون: انتهائي خرابي واري مواد لاء سفارش نه ڪئي وئي آهي (مثال, some igneous rock) without accepting higher wear costs. Requires consistent feed size to maintain optimal performance and protect components.
3. بنيادي خاصيتون
هائيڊولڪ ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: انٽيگريڊ هائيڊولڪ سلنڈرز ڪنٽرولنگ ايپرون پوزيشن | آپريشنل فائدا: Allows operators to adjust product size or clear blockages in minutes from outside the machine | ROI اثر: تائين جي ترتيب جي گھٽتائي کي گھٽائي ٿو 80% دستي شيم سسٽم جي مقابلي ۾.
مضبوط روٽر جي تعمير | ٽيڪنيڪل بنياد: Monobloc or welded steel rotor design with high mass index | آپريشنل فائدا: Delieves greater kinetic energy to material for superior reduction ratios and handles larger feed sizes with less vibration | ROI اثر: جي ذريعي امڪاني throughput وڌائي ٿو 1525% over lighterweight designs, improving circuit capacity.
MultiFunctional Crusher Housing | ٽيڪنيڪل بنياد: Hydraulically opening frame with integrated service crane | آپريشنل فائدا: Provides full, safe access to all internal wear parts and the rotor for inspection and maintenance | ROI اثر: Cuts major service time by half, translating to more tons processed between scheduled outages.
Advanced Wear Component Metallurgy | ٽيڪنيڪل بنياد: Ceramic composite or highchrome martensitic steel blow bars & apron liners | آپريشنل فائدا: Extends service life in abrasive applications by optimizing hardnesstoughness balance | ROI اثر: فيلڊ ڊيٽا ڏيکاري ٿو a 3050% improvement in wear life over standard manganese steel in equivalent duty.
سڌو ڊرائيو ٽرانسميشن | ٽيڪنيڪل بنياد: Vbelt or fluid coupling drive connecting motor directly to rotor | آپريشنل فائدا: گيئر باڪس جي سار سنڀال کي ختم ڪري ٿو, improves power transmission efficiency (>96%), and dampens shock loads | ROI اثر: Lowers lifetime operating costs through reduced component inventory and higher energy efficiency.
PLC جي بنياد تي نگراني & خودڪار انٽرفيس | ٽيڪنيڪل بنياد: Sensors for bearing temperature, وائبريشن, روٽر جي رفتار & hydraulic pressure linked to control panel | آپريشنل فائدا: Enables predictive maintenance alerts and seamless integration into plantwide SCADA systems for optimized performance | ROI اثر تباهي واري ناڪامي کي روڪي ٿو; allows datadriven planning that maximizes asset utilization.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري حل (Conventional HSI) | Our HeavyDuty Impact Crusher Solution | فائدو (% سڌارو) |
| : | : | : | : |
| زندگيءَ جو لباس (بلو بارز)| معياري مينگانيز اسٽيل / High Chrome Standard Castings| Proprietary Martensitic Alloy with Ceramic Inserts| +4060% توسيع زندگي |
| Maintenance Access Time| Manual shimming; limited access points requiring partial disassembly| Full hydraulic housing opening; integrated lifting points| 50% Service Time |
| توانائي جي ڪارڪردگي (kWh/ٽن)| وڏي پيماني تي مختلف آهي; older designs often exceed 0.81.2 kWh/ton at comparable reduction| اصلاح ٿيل چيمبر جاميٽري & direct drive targets <0.7 kWh/ٽن| تائين 25% توانائي جو استعمال |
| دستيابي (شيڊول ٿيل)| ~9092%, factoring in longer mechanical adjustments & wear changes| لاء ٺهيل >95%, via rapid adjustment & component access.| +35% اپٽائم |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: 200 - 800+ ٽي پي ايڇ (کاڌ خوراڪ جي مواد تي دارومدار & پيداوار جي ماپ)
روٽر قطر & ويڪر: 42” x 50” up to 64” x 80”
ڊرائيو پاور جي گهرج: 300 ايڇ پي - 800 ايڇ پي (225 kW - 600 ڪلواٽ), برقي موٽر
وڌ ۾ وڌ فيڊ سائيز: Up to 32” (800ايم ايم) ڪنڊ ڊگھائي
روٽر اسپيڊ رينج: جي وچ ۾ Adjustable 450 - 750 آر پي ايم
اهم مواد جي وضاحت:
روٽر جسم: ASTM A36 اسٽيل / AR400 اسٽيل
بلو بارز / ايپرون لائينر: Martensitic Steel (Cr22), مينگنيز اسٽيل (MN18), يا سيرامڪ جامع
شافٽ Forging: HighTensile Alloy Steel
بيئرنگ هائوسنگ: Cast ductile iron with spherical roller bearings
جسماني طول و عرض (لڳ ڀڳ., Model Dependent): ڊگھائي: ~12’, ويڪر:~9’, اوچائي:~10’
آپريٽنگ جي درجه حرارت جي حد: 20°C کان +45°C (4°F کان +113°F) معياري لوبريڪنٽس سان
6. درخواست جا منظر
Aggregate Producer Limestone Quarrying | Challenge A major quarry faced excessive downtime every 120 hours for blow bar rotation and replacement on their secondary impact crushers, bottlenecking their 600 TPH plant.| Solution Implementation of two heavyduty impact crushers featuring quickwedge locking systems for blow bars and hydraulic apron adjustment.| Results Blow bar changeout time reduced from 8 ڪلاڪ کان هيٺ 2 hours per machine. وڌايل لباس جي زندگي سان گڏ, crusher availability increased by 6%, yielding an additional ~35,000 tons of saleable product annually.
اڏاوت & ڊيموليشن ريسائڪلنگ ٺيڪيدار | Challenge Processing highly variable C&D feed resulted in frequent chamber blockages and erratic final product sizing at their urban recycling yard.| Solution A robust HSI crusher with a solid rotor design was selected specifically for its ability to handle large slabs of concrete rebar matting without stalling.| Results Blockage incidents fell by over . The consistent product gradation improved the marketability of their recycled aggregate base material increasing its sales price premium
Portable Crushing Contractor Challenge Their fleet of older mobile impactor plants suffered from high fuel consumption low reliability on remote job sites leadingto missed project deadlines Solution Deployment of new portable plants equippedwith modern efficient heavy duty impactors featuring direct driveand advanced wear packages Results Fuel consumption per ton crushed decreasedby an averageof . Machine reliability on critical infrastructure projects improved drastically reducing rental backup costs
7 تجارتي خيالات
Equipment pricing is structured around three primary tiers based on capacity robustnessand feature sets:
1 Entry Level Tier Designedfor lowerabrasion applications like pure limestone Includes core heavy dutyrotorand housingwith standard manganesewear parts Manual adjustment options Availablefrom $X
2 Performance Tier Our most common configuration Includes all core features listed above Hydraulic adjustment PLC monitoring premium martensiticsteelwearparts Recommendedfor mixedaggregateandrecycling Availablefrom $Y
3 Premium Custom Tier Engineeredfor maximum uptimein severe service Fully automated gap setting remote monitoring ceramic compositewearliners customfeed system integration Pricedon application basis
Optional Features Upgrades Include automatic greasing systems specialskid designs foreasier installation rock box undercrusher hoppers extendedwarranty packages
Service Support We offer tiered annual service agreements covering everythingfrom planned inspectionsand parts kits tomajor overhauls Financing throughpartner institutionsis availablefor qualified buyers covering both equipmentand installationcosts
8 FAQ
Q What primarycrusherfeed sizes are compatiblewithyour heavy dutyimpactcrushers A They are engineeredto accept directfeed fromjawcrushers setat6to8 typically handlingmaximumfeed sizesupto32 Consult oursizing guidefor specificcircuit pairing recommendations
Q How does thisimpactcrusherimprove my overallplantproduct quality A Consistent hydraulic apron control maintainsyour targetdischarge setting formore stableproductgradation This reducesloadon downstream screensand improvesyieldof inspecproductby minimizingrecirculation
Q Whatisthe typicallead timefor deliveryand installation A For standardPerformanceTier models leadtimeis approximately weeksuponorder confirmation Installationrequires dayswith preparedfoundationsby certifiedcrews Customconfigurationsvary
Q Arewearparts readilyavailableand interchangeablewithothermanufacturers A Wearparts are engineeredforspecificperformancein ourchambergeometry While dimensionalinterchange maybe possible itoften sacrificesupto ofthe designedwearlife We recommendgenuinepartsfor guaranteedperformance
Q Do youoffer financingor leasingoptions forequipmentacquisition A Yes we workwithseveralindustrial lendingpartners toofferflexiblefinancing solutionsincluding capital leases operatingleasesand loansto suitvarious balance sheetpreferences
Q Can existingplantcontrolsystems integratewiththe crushersPLC A The control systemis designedwithstandard communication protocols Modbus TCPIP typically allowingdirectintegrationinto mostmodernplantSCADA systemsfor centralizedmonitoringand control
