1. PAINPOINT DRIVEN OPENING

Managing a limestone quarry or processing plant presents distinct operational challenges that directly impact your bottom line. Are you contending with inconsistent feed material causing frequent crusher blockages and unplanned downtime? Are maintenance costs for primary crushing equipment escalating due to abrasive wear from silica content? Is your production bottlenecked by the inability to handle large, irregularly sized runofquarry rock efficiently? These issues translate into quantifiable losses: hours of lost production, excessive liner replacement costs, and compromised final product yield. The core question for plant managers is how to achieve reliable, hightonnage primary reduction while controlling operational expenditure and maximizing asset uptime.

2. PRODUCT OVERVIEW

This product is a heavyduty, white label Primary Jaw Crusher engineered specifically for the initial reduction of blasted limestone in quarry and mining applications. Its operational workflow is designed for robustness: (1) Large runofquarry limestone is fed into the vibrating grizzly feeder, which bypasses subsize material. (2) Oversize rock is directed into the deep crushing chamber of the jaw crusher. (3) A highinertia flywheel and optimized kinematics drive a aggressive elliptical motion to compress and fracture the rock against the fixed jaw plate. (4) Crushed material discharges at a preset closed side setting (CSS), ready for secondary processing.

Application scope includes primary crushing of medium to high abrasiveness limestone in stationary and semimobile plant configurations. Key limitations: not designed for sticky materials without prescreening, and maximum feed size is constrained by the specific model's gape dimension.

3. CORE FEATURES

HeavyDuty Frame & StressRelieved Construction | Technical Basis: Finite Element Analysis (FEA) optimized design with normalized steel fabrication | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading, ensuring structural integrity over a 20+ year service life | ROI Impact: Reduces risk of catastrophic frame failure, protecting your longterm capital investment.

QuarryGrade Eccentric Shaft | Technical Basis: Forged from highstrength alloy steel, supported by oversized spherical roller bearings | Operational Benefit: Sustains peak loads from uncrushable objects without shaft deflection or bearing seizure | ROI Impact: Minimizes downtime from tramp metal events; extends major bearing service intervals by approximately 40%.

WedgeLock Jaw Die System | Technical Basis: Mechanically locked wedge system secures front and rear jaw plates without backing resin | Operational Benefit: Enables singleshift jaw plate reversal or replacement, reducing maintenance time by up to 60% compared to bolted systems | ROI Impact: Increases crusher availability and lowers labor costs per ton crushed.

Aggressive Toggle Plate & Angle Design | Technical Basis: Optimized nip angle and deep symmetrical crushing chamber geometry | Operational Benefit: Promotes efficient drawdown of material, reduces bridging, and increases throughput capacity per unit of installed power | ROI Impact: Delivers higher production rates (typically 515%) within the same physical footprint.

Integrated Motor Base & Belt Guard | Technical Basis: Unified baseplate for crusher, motor, and sheaves with OSHAcompliant guarding | Operational Benefit: Simplifies installation alignment, enhances site safety, and protects drive components from environmental debris | ROI Impact: Reduces installation time and costs; mitigates safety incident risk.

Hydraulic Toggle Adjustment System (Optional) | Technical Basis: Hydraulic cylinder replaces conventional manual toggle plates for CSS adjustment | Operational Benefit: Allows remote adjustment of crusher setting in minutes for product size changes or clearing a stall | ROI Impact: Maximizes plant flexibility and operational uptime; eliminates manual shim handling.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Primary Jaw Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner ChangeOut Time| 1624 hours with bolted system| 68 hours with WedgeLock system| ~65% faster |
| Tons Crushed per kW/h| Baseline reference| Optimized kinematics & chamber design| Up to 12% more efficient |
| Bearing L10 Life Rating| Standard duty ratings| Oversized bearings with improved sealing| 3040% longer life |
| Uptime Availability| ~9294% (with planned maintenance)| >96% (demonstrated in field data)| 24 percentage points higher |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 300 1,800 MTPH (varies by feed gradation and material density)
Feed Opening: 42” x 48” up to 60” x 80”
Max Feed Size: Up to 85% of gape width
Power Requirement: 150 kW to 350 kW (200 HP to 450 HP), depending on model
Crusher Frame: Fabricated steel plate, stressrelieved
Shaft Material: Forged EN24/4340 equivalent alloy steel
Jaw Plates: Manganese steel (14%18%), multiple tooth profiles available
Approximate Weight: 45,000 kg to 120,000 kg
Operating Temperature Range: 20°C to +45°C (4°F to +113°F)
Dust Management: Prepared for dry dust suppression system connection

6. APPLICATION SCENARIOS

HighSilica Limestone Quarrying Operation

Challenge: A major aggregate producer faced excessive wear on jaw dies every 68 weeks due to high quartz content (>15% silica), causing frequent shutdowns and high consumable costs.
Solution: Implementation of our Primary Jaw Crusher with Xtralloy® premium manganese jaws and optimized flow dynamics.
Results: Achieved a consistent wear life extension to 1214 weeks between changes—a >70% improvement—reducing annual consumable cost by an estimated $42,000 USD.

Integrated Cement Plant Raw Material Handling

Challenge: Plant needed consistent 8” raw meal feed but experienced bottlenecks from bridging in the primary crusher chamber when processing claycontaminated limestone.
Solution: Installation of our Primary Jaw Crusher featuring an aggressive stroke profile and deep chamber design.
Results: Eliminated chronic bridging events. Field data shows throughput increased by an average of 11%, enabling the kiln feed system to operate at full capacity without interruption.

7. COMMERCIAL CONSIDERATIONS

Our white label Primary Jaw Crushers are offered across three valueengineered tiers:
Standard Duty Tier: For consistent feed with moderate abrasion. Includes core features.
HeavyDuty Tier: Includes hydraulic toggle adjustment as standard.
Premium Duty Tier: Includes heavyduty tier features plus upgraded bearing specifications.

Optional features include automated lubrication systems, wear monitoring sensors integrated into jaw dies.
Service packages range from basic commissioning support up through comprehensive multiyear planned maintenance agreements with guaranteed parts availability.
Financing options include capital lease agreements or rentaltoown structures tailored for capital project budgeting cycles.

8. FAQ

Q1 Is this Primary Jaw Crusher compatible with my existing secondary cone crusher circuit?
A1 Yes. The discharge setting is fully adjustable to produce optimal feed size distribution for most secondary cone or impact crushers used in limestone processing.

Q2 What is the expected operational impact on my overall plant throughput?
A2 Industry testing demonstrates that reliable primary crushing can increase total plant output by preventing downstream starvation or overloads; typical gains are sitedependent but often range from 515%.

Q3 What are typical lead times for replacement wear parts?
A3 We maintain strategic inventories of common wear parts like jaw dies; standard lead times are under two weeks globally.

Q4 Do you provide engineering support for foundation drawings?
A2 Yes. Complete mechanical foundation drawings certified by our engineering team are provided prior to shipment as part of our standard scope.

Q5 Can this equipment be integrated into a semimobile skid setup?
A5 Absolutely; we offer dedicated skidmounted configurations that simplify relocation between quarry faces or satellite sites.

Q6 What are commercial terms regarding warranty?
A6 Our standard warranty covers manufacturing defects in materials/workmanship for one year post commissioning; extended warranties are available on major components like shafts and frames

Q7 How does implementation typically proceed after order placement?
A7 Our project management team follows a defined protocol covering engineering review within two weeks followed by manufacturing updates leading up shipment