پرائيويٽ ليبل Jc5000 Jaw Crusher Catalog
Private Label JC5000 Jaw Crusher Catalog
Your Crushing Operations Are Underperforming—Here’s the Cost
Every hour of unplanned downtime in your primary crushing circuit costs between $5,000 ۽ $15,000 گم ٿيل پيداوار ۾, depending on your feed tonnage and material value. If your current jaw crusher is delivering less than 85% اپ ٽائم, you are leaving significant revenue on the table. High wear rates on jaw plates force premature replacements every 3–4 months, adding $12,000–$18,000 annually in consumable costs alone. Inconsistent product gradation creates recirculation loads that reduce overall plant efficiency by 12–18%. Feed blockages from oversized material or sticky ores cause manual intervention, exposing your operators to safety risks and halting production for 30–90 minutes per incident.
Are you absorbing these costs because you believe all jaw crushers perform the same? What if a single equipment upgrade could reduce your cost per ton by 15% while extending wear life by 40%?
پيداوار جو جائزو: The Private Label JC5000 Jaw Crusher
The Private Label JC5000 is a heavyduty primary jaw crusher engineered for continuous operation in hard rock mining, مجموعي پيداوار, and construction demolition recycling. It processes feed material from 500mm to 1,200mm, reducing it to a consistent 100–250mm product in a single pass.
آپريشنل ڪم فلو:
1. فيڊ لوڊنگ: Material enters through the 1,200mm x 900mm feed opening via excavator, ڦيٿي لوڊ ڪندڙ, or conveyor
2. پرائمري کمپريشن: مقرر ٿيل جبڙو ۽ حرڪت وارو جبڙو هڪ ويشيڊ ڪرشنگ چيمبر ٺاهي ٿو; the eccentric shaft drives the pitman to generate compressive forces exceeding 350 ايم پي اي
3. مواد جي ڀڃڪڙي: Rock is crushed against the fixed jaw plate through multiple compression cycles as it descends through the chamber
4. خارج ٿيڻ جو ضابطو: بند ٿيل پاسي واري سيٽنگ (سي ايس ايس) adjusts from 75mm to 200mm via hydraulic wedges, controlling product size
5. Material Exit: Crushed material discharges onto a belt conveyor or into a surge bin for secondary processing
ايپليڪيشن جو دائرو: سخت پٿر (گرينائيٽ, بيسالٽ, ڪوارٽزائٽ), وچولي سخت پٿر (چونا پٿر, ڊولومائٽ), ري سائیکل ٿيل ڪنڪريٽ ۽ اسفالٽ, mining ores (ٽامي, سون, لوهه)
حدون: Not suitable for clayrich materials exceeding 15% نمي جو مواد; requires 6–8 weeks lead time for custom jaw plate profiles; وڌ ۾ وڌ فيڊ سائيز تائين محدود 80% فيڊ جي افتتاح جي چوٽي جي
بنيادي خاصيتون
اصلاحي ڪرشنگ چيمبر جاميٽري | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) optimized toggle plate angle and chamber profile | آپريشنل فائدا: جي ذريعي recirculating لوڊ گھٽائي ٿي 22% سڌي چيمبر جي ڊيزائن جي مقابلي ۾ | ROI اثر: Lowers energy consumption by 8–12 kWh per 100 ٽين پروسيس ٿيل
هائيڊولڪ سي ايس ايس ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: Twin hydraulic cylinders with position sensors adjust the closed side setting in under 3 منٽ | آپريشنل فائدا: دستي شيم ترتيبن کي ختم ڪري ٿو, reducing changeover time by 85% | ROI اثر: Recovers 40–60 minutes of production time per setting change
HighStrength Manganese Jaw Plates | ٽيڪنيڪل بنياد: 18% manganese alloy with chromium carbide overlay on wear zones | آپريشنل فائدا: Achieves 14,000–18,000 tons of wear life in granite applications | ROI اثر: Reduces annual consumable costs by $4,500–$7,200 per crusher
Advanced Flywheel Design | ٽيڪنيڪل بنياد: Dual flywheels with 8,500 kg·m² moment of inertia | آپريشنل فائدا: Maintains consistent crushing force during peak load cycles, reducing motor current spikes by 30% | ROI اثر: Extends motor and Vbelt life by 18–24 months
خودڪار لوڻ وارو نظام | ٽيڪنيڪل بنياد: Programmable grease injection to all bearing points at 15minute intervals | آپريشنل فائدا: دستي گريسنگ کي ختم ڪري ٿو, سار سنڀال جي مزدورن کي گھٽائڻ 3 ڪلاڪ في هفتي | ROI اثر: Prevents bearing failures that cost $8,000–$12,000 per replacement event
Reversible Jaw پليٽ ڊيزائن | ٽيڪنيڪل بنياد: Symmetrical plate geometry allows 180degree rotation | آپريشنل فائدا: Doubles usable wear life before replacement | ROI اثر: Saves $2,800–$4,500 per set of jaw plates
انٽيگريڊ ٽراپ لوھ رليف | ٽيڪنيڪل بنياد: Hydraulic relief cylinder with 350bar pressure threshold | آپريشنل فائدا: اڻ کٽندڙ شيون گذري ٿو (ڊرل بٽس, بالٽي ڏند) without structural damage | ROI اثر: Avoids $15,000–$25,000 in frame repair costs per incident
مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (200–300 HP Jaw Crusher) | Private Label JC5000 Solution | فائدو (% سڌارو) |
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| ذريعي (ٽين / ڪلاڪ) | 250-350 ٽي پي ايڇ | 320–420 tph | 20–28% higher |
| اپٽائم (سالياني اوسط) | 82-88% | 93-97% | 10-15 سيڪڙو واڌارو |
| Cost per ton (پائڻ جا حصا) | $0.18–$0.25 | $0.12–$0.16 | 33–36% reduction |
| CSS ترتيب ڏيڻ جو وقت | 15–25 minutes | 2- 3 منٽ | 85–88% faster |
| جبل پليٽ جي زندگي (گرينائيٽ) | 9,000–12,000 tons | 14,000–18,000 tons | 40–55% longer |
| Motor power consumption | 0.8-1.2 kWh/ton | 0.6-0.9 kWh/ton | 20-25 سيڪڙو گھٽ |
| Feed opening utilization | 65-75% | 80-90% | 15-20 سيڪڙو واڌارو |
ٽيڪنيڪل وضاحتون
| پيرا ميٽر | تفصيل |
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| فيڊ کولڻ | 1,200 ايم ايم x 900 ايم ايم (48" x 36") |
| وڌ ۾ وڌ فيڊ سائيز | 950 ايم ايم (37") |
| سي ايس ايس جي حد | 75- 200 ملي ميٽر (3"–8") |
| ذريعي جي گنجائش | 320–420 tph (based on CSS and material density) |
| موٽر پاور | 250–300 kW (335–400 HP) |
| موٽر اسپيڊ | 1,500 آر پي ايم (50 هز) / 1,800 آر پي ايم (60 هز) |
| سنسڪرت شافٽ جي رفتار | 220–260 RPM |
| Flywheel وزن (هر هڪ) | 4,250 ڪلو |
| ڪل وزن (صرف کولہو) | 38,500 ڪلو |
| مکيه فريم مواد | IN 10025 S355JR ساختي اسٽيل, 40mm ٿولهه |
| جبل پليٽ جو مواد | 18% من, 2% Cr, 1.2% سي (ASTM A128 گريڊ سي) |
| بيئرنگ جو قسم | گولي وارو رولر بيرنگ, SKF 23244 CC/W33 |
| Lubrication Capacity | 8 liters grease reservoir |
| آپريٽنگ جي درجه حرارت جي حد | 20°C کان +50°C (4°F کان +122°F) |
| طول و عرض (ايل x ڊبليو x ايڇ) | 3,800 ايم ايم x 2,400 ايم ايم x 3,100 ايم ايم |
| شپنگ جي ٺاھ جوڙ | 2 x 20foot containers (crusher and motor separately) |
ايپليڪيشن منظرنامو
سخت پٿر جي کوٽائي, ناروي | چيلنج: پروسيسنگ 800,000 tons/year of granite with 18% silica content caused jaw plate wearout every 2,800 ڪلاڪ, گهربل 32 hours of downtime per replacement | حل: Private Label JC5000 with 18% manganese jaw plates and reversible design | نتيجا: جيو پليٽ جي زندگي کي وڌايو ويو 4,100 ڪلاڪ (46% سڌارو); کان سالياني گھٽتائي جو وقت گھٽجي ويو 128 ڪلاڪ تائين 72 ڪلاڪ; cost per ton decreased from $0.22 جي طرف $0.14
تعميراتي ڊيموليشن ريسائڪلنگ, جرمني | چيلنج: Processing mixed demolition waste with rebar and concrete required frequent tramp iron events, causing structural damage to previous crusher every 6 مهينا | حل: JC5000 with integrated hydraulic tramp iron relief and automatic reset | نتيجا: Zero structural damage over 18 آپريشن جا مهينا; tramp iron passage time reduced from 45 منٽ تائين 4 منٽ; plant uptime increased from 79% جي طرف 94%
ڪاپر مائن, چلي | چيلنج: Primary crushing at 4,200 meters altitude with 35°C temperature swings caused lubrication failures in standard crushers | حل: JC5000 with highaltitude lubrication package and thermal expansion compensation | نتيجا: Bearing failures eliminated over 24month period; throughput برقرار رکيو 380 tph despite altitude; سار سنڀال جي خرچن ۾ گهٽتائي $18,000 سالانه
تجارتي خيالات
سامان جي قيمت جا درجا:
- معياري پيڪيج ($285,000–$315,000): Crusher assembly, 250 kW موٽر, ويبلٽ ڊرائيو, standard manganese jaw plates, بنيادي اوزار کٽ
- وڌايل پيڪيج ($345,000–$385,000): Includes hydraulic CSS system, خودڪار lubrication, wireless remote control, spare jaw plate set
- پريميئم پيڪيج ($425,000–$475,000): Full automation package with PLC control, vibration جي نگراني, oil analysis sensors, 3year wear parts warranty
- Custom jaw plate profiles for specific feed materials: $4,500–$8,000 per set
- Highaltitude modification kit (above 3,000m): $12,500
- مٽي دٻائڻ وارو نظام (پاڻي اسپري nozzles): $6,800
- Motor soft starter or VFD: $9,500-$18,000
- ريموٽ مانيٽرنگ ٽيليميٽري پيڪيج: $7,200
- سالياني سار سنڀال جو معاهدو: $18,000/سال (شامل آهي 2 معائنو, ترجيحي ٽيڪنيڪل سپورٽ)
- Fullservice agreement: $42,000/سال (سڀني مقرر ڪيل سار سنڀال شامل آهن, wear parts at cost, 48hour response guarantee)
- Training package: $6,500 (3day onsite operator and maintenance training for up to 8 اهلڪار)
- سامان ليز: 36-60 مهينن جي شرطن سان $1 خريد ڪرڻ, starting at $6,800/month
- ملتوي ادائيگي: 90ڏينهن جي ادائيگي سان گڏ 0% interest for qualified buyers
- واپاري پروگرام: تائين $45,000 استعمال ٿيل جبڑے جي ڪرشرز کي قابليت ڏيڻ جو ڪريڊٽ (200 HP or larger)
اختياري خاصيتون:
سروس پيڪيجز:
فنانسنگ جا اختيار:
FAQ
1. What is the lead time for a Private Label JC5000?
Standard production lead time is 8–10 weeks from order confirmation. تيز ترسيل (6 هفتا) a سان دستياب آهي 5% اضافي. Custom jaw plate configurations add 2–3 weeks.
2. Can the JC5000 process recycled concrete with rebar?
ها. The hydraulic tramp iron relief system passes rebar up to 25mm diameter without damage. For larger rebar concentrations, we recommend a prescreening grizzly to remove oversized steel.
3. متوقع سالياني سار سنڀال جي قيمت ڇا آهي?
تي مبني 2,000 operating hours per year in hard rock applications, annual maintenance costs average $22,000–$28,000, including jaw plate replacement (one set), بيئرنگ لوڻ, and minor repairs.
4. Does the JC5000 require a concrete foundation?
ها. A reinforced concrete foundation with minimum dimensions of 5m x 4m x 1.5m is required, with anchor bolts embedded to our provided template. Foundation design support is included with the purchase.
5. ڇا وارنٽي ڪوريج مهيا ڪئي وئي آهي?
معياري وارنٽي ڪپڙا 24 مهينا يا 6,000 ڪم جا ڪلاڪ, جيڪو پهرين اچي. Coverage includes structural frame, سنسڪرت شافٽ, ۽ بيرنگ. ڪپڙا پرزا (جبڑے جي پليٽ, ٽوگل پليٽ) خارج ٿيل آهن. توسيع وارنٽي جا اختيار موجود آهن.
6. ڇا JC5000 موجوده پلانٽ ڪنٽرول سسٽم سان ضم ٿي سگھي ٿو?
ها. The PLCbased control system supports Modbus RTU, پروفيبس, ۽ Ethernet/IP پروٽوڪول. Integration documentation and technical support are provided at no additional cost.
7. What is the noise level during operation?
تي 1 meter distance, the JC5000 operates at 85–92 dB(اي) مڪمل لوڊ هيٺ. We recommend hearing protection for operators within 15 ميٽر. Optional acoustic enclosures reduce noise to 78 ڊي بي(اي) تي 1 ميٽر.
