1. PAINPOINT DRIVEN OPENING

Are you managing the high costs and operational bottlenecks of primary rock reduction? Inefficient crushing directly impacts your entire downstream process. Common challenges include:

Excessive Downtime for Maintenance: Frequent liner changes and unplanned repairs halt your entire production line, costing thousands per hour in lost throughput.
Inconsistent Product Gradation: Poorly sized feed from the primary stage overloads secondary crushers and screens, creating recirculation loads that waste energy and capacity.
High Operational Costs: Premature wear on consumables like mantles and concaves, combined with high energy consumption per ton, erodes your profit margins.
Vulnerability to Tramp Metal & Uncrushables: Unprotected crushers face catastrophic damage from uncrushable material, leading to severe repair costs and extended downtime.

Is your primary crushing circuit a source of reliability or a recurring cost center? The right primary stone crusher machine is not just an equipment purchase; it's a strategic decision for plantwide efficiency.

2. PRODUCT OVERVIEW

The Primary Jaw Crusher is a heavyduty, compressiveforce machine designed for the first stage of size reduction in quarrying, mining, and demolition recycling operations. It processes runofmine (ROM) material directly from the blast site or feed hopper into a coarse aggregate suitable for secondary crushing.

Operational Workflow:
1. Feed Intake: ROM material (up to 80% of crusher feed opening) is loaded into the vibrating grizzly feeder (VGF), which bypasses fines and directs oversize to the crushing chamber.
2. Compressive Crushing: A reciprocating manganese steel jaw plate (moving jaw) exerts immense force against a fixed jaw plate, fracturing rock along its natural cleavage lines.
3. Discharge Setting Adjustment: The size of the crushed output is determined by the closedside setting (CSS), hydraulically adjustable to compensate for wear and change product specification.
4. Discharge & Conveyance: Crushed material exits at the bottom discharge point onto a main conveyor belt for transport to the next processing stage.

Application Scope & Limitations:
Scope: Ideal for hard, abrasive materials (granite, basalt, quartzite). Handles large feed sizes effectively. Suitable for both stationary plants and mobile tracked setups.
Limitations: Not optimal for soft, nonabrasive stone where impact crushers may be more efficient. Requires a consistent feed rate and size distribution for optimal performance. Generates more fines than gyratory crushers at comparable settings.

3. CORE FEATURES

Deep Crushing Chamber | Technical Basis: Optimized nip angle and long linear stroke | Operational Benefit: Increases capacity by providing greater volume for material reduction in each cycle | ROI Impact: Higher throughput per hour reduces costperton metric

HeavyDuty Frame Construction | Technical Basis: Fabricated from hightensile steel plate with reinforced stress points | Operational Benefit: Provides longterm structural integrity under maximum load conditions, resisting fatigue | ROI Impact: Extends machine service life beyond 20 years, protecting capital investment

Hydraulic Toggle & Adjustment System | Technical Basis: Replaces traditional mechanical toggle plates with a hydraulic ram | Operational Benefit: Allows quick, safe CSS adjustment and provides automatic overload protection by releasing under uncrushable pressure | ROI Impact: Reduces downtime for setting changes by up to 70% and prevents costly damage from tramp iron

QuarryGrade Spherical Roller Bearings | Technical Basis: Larger diameter bearings housed in precisionmachined pits | Operational Benefit: Supports higher load capacities and runs cooler than standard bearings under continuous heavy shock loads | ROI Impact: Extends bearing service life by 4060%, reducing spare parts inventory and replacement labor costs

Wedge Locking System for Jaw Plates | Technical Basis: Mechanically locked wedges secure jaw plates without backing resin | Operational Benefit: Enables faster, safer liner changes—often completed in under two hours—and ensures secure fit during operation | ROI Impact: Minimizes maintenance windows by up to 50%, increasing annual available operating hours

Integrated Motor Base & Belt Drive | Technical Basis: Crusher flywheel motor mount and vbelt drive guard are factoryassembled units | Operational Benefit: Simplifies installation alignment reduces footprint ensures correct belt tensioning from startup | ROI Impact Lowers installation time and cost eliminates premature belt wear issues

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Primary Jaw Crusher Solution | Advantage (% improvement) |
|||||
| Liner Change Time | 68 hours (mechanical toggle) | 94% | >4 percentage point increase |
| Wear Life of Jaw Plates | Based on standard manganese | Proprietary Mn22 alloy with curve profiling| Up to 30% longer life |
| Throughput at Same CSS Baseline Deep chamber & aggressive stroke Up to 10% higher capacity |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 150 1,600 Mtph
Feed Opening Range: 800mm x 500mm up to 1,500mm x 1,300mm
Power Requirement: 75 kW 300 kW (100 HP 400 HP), depending on model
Crusher Weight (Frame & Flywheels): ~20,000 kg to ~85,000 kg
Material Specifications: Main frame – Steel Plate ST52; Jaw plates – Manganese Steel Mn18Cr2 or Mn22Cr; Eccentric shaft – Forged Alloy Steel EN24
Physical Dimensions (Approx., Largest Model): Length ~6m; Width ~3.5m; Height ~3.8m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust seals rated for typical quarry conditions.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge A quarry needed to increase primary circuit throughput by25% without expanding its footprint or changing feed size Secondary crushers were being starved
Solution Installation of a single highcapacity deepchamber jaw crusher replaced two older units The hydraulic adjustment system allowed quick optimization between railroad ballastand coarse aggregate production
Results Throughput increased by30% Power consumption per ton dropped by12% The abilityto switch products in minutes captured premium market prices resulting in an18month payback period

Urban Recycling Center Processing Demolition Concrete

Challenge Processing highly variable reinforced demolition concrete caused frequent jamsand damagein existing equipment Uncrushable rebar poseda constant threat
Solution A heavyduty jaw crusherwithan automatic hydraulic overload protection system was implemented A magnetic separator was installed onthe discharge conveyor
Results The crusher hydraulically released three major tramp metal events inthe first year preventingan estimated $120000in repair downtime Product consistency improved enablingthe recycled aggregate tomeet DOTspecificationsfor base material

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are typically structured around feed opening sizeand capacity:
Tier1(Entry/Medium Duty): Forfeed openings upto~1000mm x650mm Idealfor stationary plantsor mobile units
Tier2(Heavy Duty Quarry Class): Forfeed openings upto~1300mm x1000mm Themost common rangefor highproduction aggregatesites
Tier3(Superior Primary Station): Forfeed openings exceeding1300mm Designedfor largestationary miningand megaquarry applications

Optional Features:
Hydraulic gap setting adjustment vs manual shim adjustment Automated lubrication systems Centralized greasing points Rock breaker boom systems foreliminating bridging Custom painted finishes forspecific site requirements

Service Packages:
Standard warranty covering partsand laborfor12months Extended warranty plansupto36months Onsite commissioning supervision Annual inspection contracts Remote monitoring hardware/software packages

Financing Options:
Capital purchase Leasetoown agreements Operating leases withfullservice included Consortium financing formajor projects Tradein programs forexisting equipment

8 FAQ

Q Whatis themaximum rocksize Icanfeed intoa jawcrusher?
A Themaximum feedsize shouldnot exceed80%ofthe widthofthe feedopening Forexample acrusherwitha1200mmx800mm opening canaccept lumpsofupto~960mmin width

Q Howdoesthe hydraulic toggle systemprotectthecrusher?
A Itfunctions asbothan adjustmentsystemandan overload safetydevice Whenuncrushable material enters thechamber pressure exceedsaset threshold causingthe hydraulic ramtorelease andreducetheCSS allowingthe object topass Thesystemthen automatically resets

Q Arejawcrushers suitablefor processing highly abrasive materials?
A Yes theyareexceptionally wellsuited Manganese steeljawplates workharden duringoperation developinga surface layer thatsignificantly improves wearresistancein abrasive applications Regular rotationofreversible plates extends servicelife further

Q Whatisthetypical operational noise level?
A Sound power levels typically rangebetween115125dBAatone meter dependingonmaterial beingcrushed Proper acoustic enclosuresor screening canbe specified tomeet local environmental regulations

Q Canyou provide assistancewithfoundation designand installation?
A Yes comprehensive foundation drawingsincludingallstaticand dynamic loadsareprovided as part ofthe technical documentation packagesite layout advisory servicesarealso available