ODM Quarry Ballast Crushing Equipment Manufacturers
1. PAINPOINT driven اوپننگ
آپريشنل خرچن ۾ اضافو ڪري رهيا آهن ۽ غير متوقع وقت ختم ڪري رهيا آهن توهان جي کواري جي منافعي کي? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, ballast production presents distinct challenges that directly impact the bottom line. عام درد جون پوائنٽون شامل آهن:
وڌ ۾ وڌ فائنس پيدا ڪرڻ: تائين 1520% of processed material can fall below spec, turning potential revenue into waste stockpiles.
اعلي لباس حصو واپرائڻ: The abrasive nature of trap rock, گرينائيٽ, and basalt leads to premature liner and hammer failure, بار بار سبب, costly maintenance stops.
Inconsistent Product Cubicity: Poor particle shape in the final product reduces track bed stability and can lead to product rejection.
توانائي جي گھٽتائي: Older crushing stages consume disproportionate power for the usable tonnage produced, inflating operational expenses.
Inflexible صلاحيت: Fixed plants struggle to adapt to fluctuating demand, creating bottlenecks or underutilization.
Is your current setup equipped to maximize yield from every ton of feed while controlling maintenance costs and energy consumption? The right primary crushing equipment is the foundational answer.
2. پيداوار جو جائزو: ODM QUARRY PRIMARY JAW CRUSHER FOR BALLAST PRODUCTION
This product line focuses on heavyduty primary jaw crushers engineered specifically for highvolume ballast production from hard, abrasive feed materials. As an ODM (اصل ڊيزائن ٺاهيندڙ), we provide customized crushing solutions built to your precise operational parameters and site constraints.
آپريشنل ڪم فلو:
1. ابتدائي گھٽتائي: روم (RunofMine) پٿر جي کوٽ, typically up to 800mm in size, is fed into the crusher's robust vibrating grizzly feeder (وي جي ايف ايف وي جي ايف) section.
2. پري اسڪريننگ & ڪِرڻ: VGF قدرتي جزا ختم ڪري ٿو ۽ سبسائز مواد کي پاس ڪري ٿو, ڪرشنگ چيمبر ۾ صرف وڏي وڏي پٿر کي سڌو ڪرڻ. The deep,symmetrical jaw chamber performs the initial compressive break.
3. Product Shaping: The kinematics of the jaw plate motion are optimized to promote interparticle crushing, enhancing particle cubicity on the first pass.
4. خارج ٿيڻ & پهچائڻ: Crushed material is discharged at a consistent CSS (بند طرف سيٽنگ) onto the primary conveyor for transport to secondary screening and crushing stages.
ايپليڪيشن جو دائرو & حدون:
لاء مثالي: Primary crushing of hard, ٻرندڙ آتشي پٿر (گرينائيٽ, بيسالٽ) and dense limestone for railway ballast and construction aggregates.
حدون: چپچپا لاء مناسب ناهي, claybound materials without prescreening/scalping. Feed size is constrained by crusher model inlet dimensions.
3. بنيادي خاصيتون
HeavyDuty Rolled Steel Frame | ٽيڪنيڪل بنياد: سنگل پيس, stressrelieved fabrication | آپريشنل فائدا: سائيڪل جي لوڊشيڊنگ تحت فريم ٿڪڻ جي ڀڃڪڙي کي ختم ڪري ٿو; provides stable platform for precision bearing alignment | ROI اثر: Extended structural life exceeding 20+ years reduces capital replacement risk.
اصلاح ٿيل چيمبر جاميٽري & Kinematics | ٽيڪنيڪل بنياد: ST/DT (Steep/Deeper Toggle) cavity design with aggressive nip angle | آپريشنل فائدا: تائين ذريعي ذريعي وڌائي ٿو 10% at same power draw; promotes better particle shape for downstream processing | ROI اثر: Higher yield of inspec product per operating hour directly increases revenue.
Hydroset CSS Adjustment System | ٽيڪنيڪل بنياد: Hydraulic cylinders support the toggle seat for safe setting adjustment | آپريشنل فائدا: Closedside setting changes can be made in minutes under load or during clearing strokes, without manual shims | ROI اثر: پراڊڪٽ جي سائيز جي تبديلين لاءِ دير جو وقت گھٽائي ٿو 80%, enhancing plant flexibility.
LongLasting Manganese Jaws with Clamp Systems | ٽيڪنيڪل بنياد: Isovitric supergrade manganese steel with reversible design; mechanical clamp system for fast replacement | آپريشنل فائدا: Jaw life increased by 2530%; changeout time reduced from days to a single shift | ROI اثر: Lowers costperton for wear parts and significantly increases plant availability.
Integrated PreScreening Grizzly Feeder | ٽيڪنيڪل بنياد: Boltin grizzly sections with adjustable slope and gap settings | آپريشنل فائدا: Removes up to 20% of fines prior to crushing chamber, reducing unnecessary wear and improving chamber efficiency | ROI اثر: Directly lowers wear part consumption and power cost per ton of crushed material.
مرڪزي خودڪار گريسنگ سسٽم | ٽيڪنيڪل بنياد: Programmable lubrication unit serving all key bearing points | آپريشنل فائدا: بهترين بيئرنگ لوبريڪيشن وقفن کي يقيني بڻائي ٿو; prevents both under and overgreasing failures | ROI اثر: Extends critical bearing service life by an average of 35%, preventing catastrophic downtime.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (سراسري) | ODM Quarry Jaw Crusher Solution | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي (اپٽائم) | ~ 8590% (مقرر & اڻ شيڊول اسٽاپ) |> 94% (based on field monitoring data) |> +5% سڌارو |
| لباس جي قيمت في ٽون (ابراھيندڙ پٿر) $0.12 $0.18/ٽين| 25% گھٽتائي |
| مخصوص پاور واپرائڻ| وڏي پيماني تي مختلف آهي; older units > 0.8 kWh/ton @ CSS 150mm| 19% گھٽتائي |
| فني نسل (<22ايم ايم)| ~1822% of total feed| 30% گھٽتائي |
| Product Flakiness Index (نشانو 30% after primary stage| Consistently Improved Shape |
5. ٽيڪنيڪل وضاحتون
ماڊل رينج جي گنجائش: 400 1,800 ٽين في ڪلاڪ (ٽي پي ايڇ), depending on feed material and closedside setting.
فيڊ کولڻ: 1,000mm x 650mm کان 1,500mm x 1,200mm تائين.
بجلي جي گهرج: Drive motor from 90 kW تائين 300 ڪلواٽ; total installed power including feeder hydraulics specified per model.
مواد جي وضاحت: اعلي طاقت ويلڊڊ فريم (S355JR اسٽيل); Isovitric manganese crusher jaws; forged alloy steel eccentric shaft with largediameter spherical roller bearings.
جسماني طول و عرض & وزن: Approximate weights from 35 ٽين تائين 120 ٽين; detailed layout drawings provided for foundation planning.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dust sealing compliant with ISO standard levels; noise emissions designed below 105 ڊي بي(اي) آپريٽر اسٽيشنن تي.
6. درخواست جا منظر
Hard Rock Quarry Supplying National Rail Project
چيلنج: A granite quarry needed to supply over 2 million tons of Type I ballast within a strict timeline but faced excessive wear costs and fines generation (>22%) from their existing primary crusher.
حل: Implementation of a customconfigured ODM heavyduty jaw crusher with an integrated aggressive grizzly feeder profile optimized for their specific granite blend.
نتيجا: Fines generation reduced to below spec at <14%. Wear part lifecycle extended by approximately28%. The project was completed ahead of schedule due to sustained throughput rates averaging12% above target.
Aggregate Producer Expanding into Rail Ballast Market
چيلنج: An established aggregate producer lacked a primary stage capable of producing the consistent cubicity required by rail authorities without excessive secondary recrushing.
حل: Installation of an ODM jaw crusher with a specially engineered chamber profile focused on firstpass shape optimization.
نتيجا: Final product Flakiness Index achieved directly after primary crushing met rail specification (<25%), reducing load on secondary cone crushers by approximately15%. This allowed reallocation of secondary capacityto other product lines.
7. تجارتي خيالات
Our ODM approach provides structured commercial flexibility:
سامان جي قيمت جا درجا: Based on model size/capacity range:
ٽائر I (1200 ٽي پي ايڇ): Fully customized solutions with advanced monitoring packages included.
اختياري خاصيتون & پيڪيجز:
Advanced PLC automation package with loadregulation logic
Wear part monitoring sensors
مٽي دٻائڻ وارو نظام انضمام
Modular skidbase design for faster installation
سروس پيڪيجز:
Basic Warranty Package
Comprehensive Service Agreement including scheduled inspectionsand parts discounts
ٽرنڪي جي انسٽاليشن & ڪميشن جي حمايت
فنانسنگ جا اختيار:
We work with international export credit agenciesand equipment financing partners t o offer leasetoown arrangements , mediumterm loans , or tailored rentalpurchase agreements t o align w ith your project cash flow .
8.FAQ
ق:What level o f customization i s possible w ith your ODM jaw crushers?
A.We can modify several parameters including feeder dimensions ,grizzly bar configuration ,discharge conveyor interface points ,and motor mounting positions t o ensure compatibility w ith your existing plant layoutand feed system .
Q.How does this equipment improve our overall plant efficiency beyond justtheprimary stage?
A.B y deliveringa more consistent ,cubicalproductatthefirststage,yoursecondaryand tertiarycrushers operate more efficiently .This reduces circulating loadsand improves finalproductyieldwhile loweringtotalplantpowerconsumption .
ق:What i sthetypical delivery lead timeforacustomized unit?
A.Forstandardmodels withinourTierI&IIrange ,lead timesaretypically1622weeksfromorderconfirmation .FullycustomizedTier IIIsolutionsrequire detailed engineeringand mayextendto28weeks .Proactive planningi srecommended .
Q.Arewearparts interchangeablewithothercrusherbrands?
A.No .Ourwearpartsaredesigned specificallyforourchambergeometryandkinematics t oensureoptimalperformanceand longevity .We providecomplete technicaldrawingsforinventory planning .
Q.What kindo f foundationi srequired ?
A.We providecomprehensivefoundationdrawingswitheachorderincludingallstaticand dynamicloaddata .Foundationsaretypicallyreinforcedconcrete ;our engineerscanreviewyoursitespecificplansuponrequest .
Q.Doyouoffertrainingforouroperatorsandmaintenancestaff ?
A.Y es.O nsiteoperationalandsafetytrainingduringcommissioningi sincludedwith everysale .Additionalmaintenancetrainingmodulesareavailableaspartofourservicepackages .
Q.Whatarethekeyfactorsin determiningthecorrectmodelsizeforourapplication ?
A.Capacityselectionisbasedonfourprimaryfactors :yourmaximumfeedsizematerialhardnessorBWI( BondWorkIndex ),desiredproductsize( سي ايس ايس ),andrequiredhourlytonnage .Ourtechnicalteamwillanalyze yoursamplesandspecificationst orecommendtheoptimalmodel
