H1: White Label Hammer Mill | HighCapacity, LowCostPerTon Size Reduction

1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your margins in size reduction? For plant managers and contractors, the challenges with standard hammer mills are quantifiable:
Excessive Downtime for Maintenance: Frequent screen changes and wear part replacement halt production, costing thousands per hour in lost throughput.
High Operational Costs: Premature wear on hammers, screens, and linings due to inefficient design or substandard materials creates a continuous cycle of parts expenditure.
Inconsistent Product Gradation: Uncontrolled particle size distribution and overheating can compromise final product quality, leading to rejects and customer dissatisfaction.
Rigid Application Scope: A mill that cannot adapt to varying feed materials or moisture content forces suboptimal operation or capital investment in multiple machines.

Is your current crushing solution delivering a predictable costperton? Can it handle feedstock variability without sacrificing efficiency or requiring constant adjustment? The right white label hammer mill directly addresses these operational and financial pressures.

2. PRODUCT OVERVIEW

This white label hammer mill is a heavyduty industrial crusher engineered for highvolume reduction of mediumhard to soft materials. It transforms raw feedstock into a consistent, predetermined particle size through impactbased fragmentation.

Operational Workflow:
1. Controlled Feed: Bulk material is introduced via vibratory feeder or conveyor into the mill’s reinforced feed hopper.
2. Impact Fragmentation: Rapidly rotating hammers (rotor assembly) strike the material, shattering it against the static breaker plates.
3. Size Classification: Sized particles pass through the interchangeable screen grate encircling the rotor chamber, determining the maximum output size.
4. Discharge & Conveyance: Reduced material exits the mill housing for transport to the next stage via pneumatic system or conveyor.

Application Scope: Ideal for processing aggregates, limestone, recycled construction materials, certain industrial minerals, and biomass. Effective on materials with Mohs hardness up to ~45.

Key Limitations: Not suitable for highly abrasive materials (e.g., silica sand), very hard rocks (e.g., granite), or ductile metals without significant design modification and accelerated wear cost acceptance.

3. CORE FEATURES

Dynamic Balancing System | Technical Basis: Computeraided rotor balancing at operational RPM | Operational Benefit: Eliminates destructive vibration, extends bearing life by up to 40% | ROI Impact: Reduces unscheduled maintenance events and major component replacement costs

QuickChange Wear Part System | Technical Basis: Toolless access panels and pinned hammer/screen retention | Operational Benefit: Reduces screen and hammer changeover time from hours to under 30 minutes | ROI Impact: Increases machine availability, directly boosting annual throughput capacity

Directional Rotor & Dual Grinding Paths | Technical Basis: Reversible motor and symmetrical chamber design | Operational Benefit: Operators can reverse rotor direction to utilize both edges of hammers; dual grinding paths optimize wear distribution | ROI Impact: Doubles effective service life of hammer sets, cutting consumable costs per ton by nearly half

HeavyDuty Screen Cartridge System | Technical Basis: Segmented, reinforced screen modules with uniform perforation | Operational Benefit: Provides consistent gradation; individual segments can be replaced independently if damaged | ROI Impact: Lowers screen replacement costs by 3050% compared to singlepiece designs

Laminated Steel Housing with AbrasionResistant Liners | Technical Basis: Multilayer housing with bolton AR400 steel liners at impact zones | Operational Benefit: Contains noise (<85 dB at 1m typical), contains dust, protects structural integrity from abrasion | ROI Impact: Prevents catastrophic housing failure, a major repair expense; extends total mill service life

PLCReady Drive & Monitoring Interface | Technical Basis: Integrated sensors for vibration, temperature, and amperage draw with standard communication protocols (e.g., Modbus) | Operational Benefit: Enables predictive maintenance scheduling and integration into plantwide automation systems | ROI Impact: Prevents costly secondary damage from component failure; optimizes power consumption

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | This White Label Hammer Mill Solution | Documented Advantage |
| : | : | : | : |
| Total Cost of Ownership (5 yr.)| High Frequent parts replacement & downtime| Optimized Extended wear life & fast service| Up to 25% reduction |
| Specific Energy Consumption (kWh/ton) | Varies widely with feed; often inefficient| Controlled via optimized rotor kinetics & airflow| 1015% improvement |
| Mean Time Between Failure (MTBF) Bearings| ~2,0003,000 operating hours| >4,200 operating hours (field data)| ~40% increase |
| Wear Part Changeover Time (Full Set)| 46 hours with multiple personnel| <90 minutes with 2 personnel| ~70% time savings |
| Product Consistency (Gradation)| Can shift with screen wear/hammer wear| Stable due to directional rotor & screen design| Variance improved by up to 60% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent from 15 TPH to over 150 TPH of crushed aggregate.
Power Requirements: From 75 kW (100 HP) to 450 kW (600 HP), 3phase electric motor drive. Voltage as per regional standards.
Rotor Specifications: Solid steel forging or fabricated steel plate; diameter from 800mm to 1500mm; width from 600mm to 2500mm.
Material Specifications:
Housing: ASTM A36 carbon steel with bolton AR400/500 liners.
Hammers/Screens/Breaker Plates: Highchrome cast iron or manganese steel options based on application abrasiveness.
Physical Dimensions (Typical Large Model): Approx. Length: 3.5m x Width: 2.8m x Height: 2.2m (excluding feed/discharge).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dustproofed bearings and electrical components standard.

6. APPLICATION SCENARIOS

Construction & Demolition Recycling Plant | Challenge: Inconsistent feed of concrete rubble mixed with rebar fragments causing frequent jamming and rapid hammer degradation in existing mill. Solution: Implementation of a white label hammer mill equipped with heavyduty "ripper" hammers designed for shock loading and an overloadprotected rotor shaft. Results Jamming incidents reduced by over 90%. Hammer life extended from ~250 hours to over ~600 hours on similar feedstock—achieving target product size at a sustained throughput of ~65 TPH.

Agricultural Limestone Processing Facility Challenge Seasonal moisture variation in quarried limestone led to screen blinding in traditional mills halting production for manual cleaning multiple times per shift Solution Deployment of a white label hammer mill featuring the directional rotor system for clearing sticky material airflow management technology Results Screen blinding events were virtually eliminated allowing continuous operation Rotor reversal feature enabled full utilization of hammer edges reducing consumable orders by an estimated $12 annually

Lightweight Aggregate Manufacturing Challenge Producing consistent spec pumice granules required multiple crushing stages leading high energy costs excessive fines generation Solution A singlestage white label hammer mill configured with a specialized finegrinding screen profile precise internal airflow control replaced two older crushers Results Achieved target gradation in one pass reducing overall plant energy consumption by Specific fines generation was cut by improving saleable product yield

7 COMMERCIAL CONSIDERATIONS

Pricing is structured around throughput capacity drive power configuration
Tier Basic Model Standard duty components manual maintenance access
Tier Professional Model Includes quickchange systems directional rotor PLC interface
Tier HeavyDuty Model Upgraded material specs throughout enhanced predictive monitoring package
Optional Features Magnetic separator tramp metal protection advanced vibration monitoring cartridge dust collection shroud custom screen perforations
Service Packages Available include scheduled preventive maintenance programs remote diagnostics support bulk pricing agreements on verified wear parts kits
Financing Options Flexible leasing structures operating lease agreements are available allowing you preserve capital while deploying equipment immediately

8 FAQ

What is the lead time for delivery of a customconfigured white label hammer mill?
Standard configurations ship within weeks Complex custom builds require consultation but benefit from modular design principles that streamline manufacturing

How does this equipment integrate with our existing conveyor screening plant?
The mills are designed standard inlet outlet dimensions flanges They feature PLCready controls allowing straightforward integration into most existing control systems via common industrial protocols

What is your process for determining correct model specifications our material?
Our engineering team requires kg sample detailed analysis including moisture content hardness abrasiveness desired output PSD This data informs precise model selection ensuring performance guarantees are met

Can you provide documented case studies total cost ownership versus competitor models?
Yes We maintain anonymized field data reports covering specific energy consumption mean time between failure MTBF key components consumable cost per ton metrics across various applications These are available prospective commercial clients under NDA

What warranty coverage provided what does include?
We offer comprehensive month warranty structural components months moving parts electrical items Warranty requires use genuine parts adherence recommended maintenance schedule documented commissioning