1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges in primary crushing often stem from the initial reduction stage. Inefficient or unreliable primary crusher performance creates cascading bottlenecks throughout your entire processing circuit.

Common operational challenges include:
High Downtime for Maintenance: Frequent liner changes and unplanned stops for jam clearing can consume over 15% of available production time annually.
Inconsistent Feed Handling: Fluctuating feed size, moisture, and hardness lead to chokefeeding, wear imbalances, and suboptimal throughput.
Excessive Energy Consumption: An inefficient crushing chamber design or misapplied technology can increase power costs by 2030% per ton of material processed.
High Wear Part Costs: Rapid abrasion of jaws, mantles, and concaves in abrasive formations results in unsustainable consumables expenditure.
Limited Configuration Flexibility: Fixed plants struggle to adapt to changing deposit profiles or new project specifications, locking you into a single operational mode.

Is your primary crushing station a source of constant adjustment and cost, or a reliable foundation for your plant’s profitability?

2. PRODUCT OVERVIEW: Primary Jaw Crusher Station

A Primary Jaw Crusher Station is a fixed or modular assembly designed for the first stage of size reduction in hard rock quarries, mining operations, and largescale construction projects. Its function is to accept runofmine (ROM) material directly from the quarry face and reduce it to a manageable size for secondary crushing and conveying.

Operational Workflow:
1. Feed Intake: Dump trucks or loaders deposit large (up to 1.5m) ROM material into a rugged vibrating grizzly feeder (VGF).
2. PreScreening & ByPass: The VGF separates fines (< CSS) to bypass the crusher, reducing wear and improving overall efficiency.
3. Primary Crushing: Oversize material is directed into the jaw crusher’s cavity, where a reciprocating jaw exerts immense compressive force against a fixed jaw, breaking rock along its natural fracture lines.
4. Discharge & Conveyance: Crushed product is discharged onto a main conveyor at a controlled rate for transport to the next stage.

Application Scope & Limitations:
Scope: Ideal for hightonnage processing of hard, abrasive materials like granite, basalt, and iron ore. Suited for stationary plants with longlife quarries.
Limitations: Not optimal for soft, nonabrasive rock or highly laminated/cleaved material where impact crushing may be more efficient. Requires substantial foundational support and is less mobile than some alternatives.

3. CORE FEATURES

Deep Crushing Chamber & Aggressive Nip Angle | Technical Basis: Optimized kinematics for increased compressive force | Operational Benefit: Handles larger feed sizes with fewer bridging incidents; produces a consistent, wellgraded output on the first pass | ROI Impact: Reduces need for prebreaking or secondary hammering; lowers costperton in the primary stage.

HeavyDuty Fabricated Steel Frame | Technical Basis: Finite Element Analysis (FEA)designed stress distribution | Operational Benefit: Provides unwavering stability under peak loads, minimizing frame fatigue and alignment issues over a 20+ year service life | ROI Impact: Eliminates costly structural repairs; protects major capital investment.

Hydraulic Adjustment & Clearing System | Technical Basis: Integrated dualacting hydraulic cylinders | Operational Benefit: Allows operators to adjust the closedside setting (CSS) remotely for product size changes and safely clear blockages in minutes without manual intervention | ROI Impact: Cuts nonproductive downtime by up to 80% during routine adjustments and stall recovery.

BoltOn Wear Liners & Modular Cheek Plates | Technical Basis: Highstrength alloy steel castings with reversible design | Operational Benefit: Enables fast replacement with standard tools; extends service intervals through multiple rotation cycles | ROI Impact: Reduces liner changeout time by over 50%; lowers inventory costs through part commonality.

Centralized Automated Greasing System | Technical Basis: Programmable lubrication pump with feed lines to all critical bearings | Operational Benefit: Ensures optimal bearing health with precise grease volume control, independent of operator routine | ROI Impact: Prevents premature bearing failure—a leading cause of major crusher repair—extending component life by an average of 40%.

Toggle Plate Safety System | Technical Basis: Mechanically sacrificial cast iron toggle plate | Operational Benefit: Acts as a mechanical fuse; fractures under uncrushable overload (e.g., tramp metal), protecting the crusher from catastrophic damage | ROI Impact: Avoids weeks of downtime and sixfigure repair bills associated with frame or shaft damage.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Primary Jaw Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Availability (Uptime) | ~8588% due to maintenance & jams| >92% with hydraulic adjustment & clearing| +57% more productive hours |
| Wear Life (Abrasive Rock) | 120,000 150,000 tons per set| 180,000 220,000 tons per set| +40% longer service intervals |
| Energy Efficiency (kWh/ton)~| Varies widely; baseline = X kWh/ton~| Field data shows X15% kWh/ton~| Up to 15% lower power consumption |
| Throughput Capacity (tph)~| Rated at ideal conditions~| Sustained throughput at rated capacity in realworld feed conditions~| +1012% higher effective yield |

_Based on comparative field studies in granite quarries._~
_~Specific values depend on model selection and material characteristics._

5. TECHNICAL SPECIFICATIONS

Capacity Range: 500 1,600 Metric Tons per Hour (MTPH), depending on model and feed gradation.
Feed Opening: From 1,000mm x 650mm up to 1,500mm x 1,200mm.
Power Requirements: Main crusher motor from 90 kW up to 300 kW. Total station power including VGF and conveyors typically ranges from 200 kW to 450 kW.
Material Specifications: Main frame constructed from hightensile strength steel plate (Min. yield strength 355 MPa). Wear parts available in several manganese steel grades (14%,18%,22%) for optimal cost/performance matching.
Physical Dimensions (Typical Station): Length ~25m; Width ~8m; Height ~7m (excluding discharge conveyor).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system ready. Noise emissions compliant with <85 dB(A) at operator stations.

6. APPLICATION SCENARIOS

Granite Quarry Expansion

Challenge: A large granite quarry needed to increase primary circuit throughput by 25% without expanding its footprint or changing feed size from new blasting patterns.
Solution: Implementation of a highcapacity singletoggle jaw crusher station with an optimized grizzly feeder section to improve feed distribution.
Results: Achieved a sustained throughput increase of 28%. Wear part consumption per million tons decreased by an estimated18%, meeting expansion goals within the existing layout.

Iron Ore Processing Plant Retrofit

Challenge: Chronic downtime due to tramp steel causing catastrophic damage in the existing primary crusher,
averaging12 days of lost production annually.
Solution:
Retrofit installation featuring an enhanced tramp release system using energyabsorbing hydraulic cylinders
and an automatic reset function.
Results:
Eliminated major damage events.Recovery from uncrushable objects now takes less than
30 minutes.Incidentrelated downtime reduced by over95%.

7.COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are primarily determined by capacity size
and customization level:

• Tier I(Standard Duty):For consistent,friable material.Highest cost efficiency
for defined applications.

• Tier II(Heavy Duty):Our most common selection
for hard rock quarries.Includes standard hydraulic adjustment
and heavier components.Balances performance
with durability

• Tier III(Modular/SkidMounted):Designed
for faster installation
or semimobile requirements.Priced accordingly

Optional Features:

• Automated wear monitoring systems

• Advanced motor starters(VSD)

• Integrated dust suppression packages

Service Packages:

• Commissioning & Operator Training

• Planned Maintenance Agreements(with guaranteed parts availability)

• Remote Performance Monitoring Subscription

Financing Options:

Capital expenditure can be structured through equipment leasing programs,
longterm rentaltoown agreements,
or project financing partnerships tailored
for largescale infrastructure development

8.FAQ

Q1:
How do I determine if this type is suitable versus gyratory crusher?
A:Gyratory crushers excel at very high tonnage(>1，500 tph)
in mining.Jaw stations offer lower capital cost，
simpler maintenance，
and better handling
of slabby material，
making them preferred
for most quarry applications up
to ~1，200 tph

Q2:
What infrastructure is required?
A:A substantial reinforced concrete foundation capable
of supporting dynamic loads，
adequate crane access
for wear part replacement，
and integration points
for raw feed supply
and crushed product conveyors are essential

Q3:
Can it handle wet，sticky material?
A：While capable，
excessive clay or moisture significantly increases risk
of packing/choking.A robust vibrating grizzly feeder(scalper)
is critical，
and alternative primary crushing types may be recommended

Q4：
What is typical installation timeline？
A：For complete station including foundation，
allow8–14 weeks from delivery depending on site readiness.Modular skid versions can reduce this timeline significantly

Q5：
How are wear parts priced？
A：Parts are offered under transparent pricing models—either fixedprice per operating hour agreements（cost certainty）or direct purchase.Consumables cost per ton processed should be calculated during application review