Jaw Crushers
Sealed Jaw Crusher for Laboratory Material Crushing and Sample Preparation
Item Number: PP-JA13
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Product Overview
The sealed jaw crusher is a laboratory-scale apparatus designed for primary crushing of medium-hard to hard brittle materials. Serving as a workhorse in sample preparation workflows, it utilizes a single-toggle curved extrusion motion to apply high mechanical force to specimens, reducing them to a homogenous granular state. Its fully sealed body design minimizes dust emission, ensuring a cleaner and safer working environment compared to open-frame crushers.
This system is widely adopted across industrial and academic laboratories that require consistent particle size reduction for subsequent analysis or processing. Typical users include coal testing facilities, metallurgical plants, geological survey organizations, cement manufacturers, and materials research institutes. By delivering reproducible crush sizes, it forms a reliable foundation for spectroscopic, X-ray diffraction, wet-chemical, and physical testing methods.
Constructed around a massive cast-iron frame with shock-absorbing mounts, this unit maintains stable operation even under continuous heavy-duty use. Its core components, including the eccentric shaft, bearings, and jaw plates, are precision-machined and rigorously inspected to ensure minimal wear and long-term accuracy. Laboratories worldwide count on its robust engineering for decades of dependable service.
Key Features
- Optimized Crushing Chamber: The deep symmetrical crushing zone maximizes particle-to-particle crushing, reducing flake-shaped output and improving reduction ratios. This geometry also minimizes jaw plate wear by distributing forces evenly.
- Adjustable Discharge Mechanism: A wedge-based gap adjustment system allows stepless setting of the outlet width from 8 to 40 mm with simple hand tools. This lets operators quickly match the output size to specific mesh requirements without disassembling the crusher.
- Industrial Grade Jaw Plates: Standard plates are cast from high-manganese steel (Hadfield steel), which work-hardens under impact and exhibits extraordinary abrasion resistance. This metallurgy extends service life threefold over ordinary carbon steel in demanding lab environments.
- Sealed Design with Integrated Dust Control: The crushing chamber is enclosed by heavy-gauge sheet metal with gasketed access doors, containing over 95% of generated dust. An optional dust extraction flange allows connection to a central vacuum system for regulated workplaces.
- High-Efficiency Drive System: A 5.5 kW TEFC induction motor coupled to a large flywheel via V-belts provides torque amplification during the crushing stroke. This ensures consistent momentum even when processing tough materials up to 100 MPa compressive strength.
- Broad Feed Compatibility: The generous 150×250 mm feed opening accepts samples as large as 125 mm, eliminating the need for preliminary splitting of most field specimens. This saves time and reduces the number of handling steps.
- Rugged Construction for Continuous Duty: Key stress components like the main frame, eccentric shaft, and toggle seats are manufactured from normalized cast steel and fitted with oversized anti-friction bearings. The design is validated for 24/7 operation in high-throughput testing facilities.
- Low Maintenance Requirements: All lubrication points are grouped at a centralized grease block, and jaw plates are reversible to double their wear life. Routine service can be performed by lab personnel without specialized tools.
- Adaptable Electrical Configuration: The standard 380V, 50 Hz three-phase motor can be rewired for other voltages and frequencies on request, making the unit suitable for international installations. Optional explosion-proof motors are available for hazardous-area applications.
Applications
| Application | Description | Key Benefit |
|---|---|---|
| Coal quality assessment | Crushing raw coal samples to <10 mm for proximate analysis (moisture, ash, volatile matter) and calorific value tests in power generation and coking labs. | Produces homogenous particle distribution, minimizing sampling error and ensuring reproducible analytical results. |
| Mineral exploration sample prep | Reducing drill core and chip samples of copper, gold, iron, and other ores to a size suitable for pulverizing before fire assay or ICP-OES analysis. | Handles hard silicate rocks up to 100 MPa, delivering high throughput during field camp processing seasons. |
| Cement raw material testing | Preparing limestone, clay, and iron ore mixtures for mill control in cement plants, where consistent particle size is critical for accurate XRD and XRF pellet analysis. | Adjustable gap ensures optimization for the target fusion bead or pressed pellet protocol. |
| Ceramic powder processing | Crushing frits and fired ceramic bodies into uniform granules for subsequent fine grinding in planetary ball mills, used in advanced ceramics R&D. | Low contamination design prevents cross-material pollution, crucial for high-purity ceramic batches. |
| Environmental soil analysis | processing dried soil and sediment samples for heavy metals and pesticide residue screenings in ISO 17025 accredited labs. | Sealed chamber and dust containment prevent lab contamination and protect operator health. |
| Aggregates and concrete testing | Breaking down gravel and recycled concrete samples to evaluate crushing strength and particle shape per ASTM C29 and C136. | Robust construction tolerates abrasive quartzite and basalt aggregates without jamming. |
| Coke and carbon materials | Reducing petroleum coke and metallurgical coke specimens for sieve analysis and carbon/sulfur determinator feed preparation. | Pre-breaker replacement eliminates manual hammer sizing, improving lab safety and sample integrity. |
| Education and training | Used in university material science labs for student experiments on comminution theory, energy consumption, and particle size distribution analysis. | Simple, safe operation with clear access to the crushing zone allows students to observe the mechanism directly. |
Technical Specifications
The specifications below define the standard configuration of this sealed jaw crusher. Alternative jaw plate materials (e.g., chrome steel, tungsten carbide) and custom voltage/frequency options are available upon request.
| Parameter | Value |
|---|---|
| Model | PP-JA13 |
| Jaw Plate Material | High-Manganese Steel (standard) |
| Feed Opening Size | 150 × 250 mm |
| Maximum Feed Size | ≤125 mm |
| Discharge Opening Range | 8 – 40 mm (adjustable) |
| Production Capacity | 1.5 – 4 T/h |
| Motor Power | 5.5 kW |
| Supply Voltage | 380 V, 50 Hz (other voltages available) |
| Crushing Motion | Curved extrusion / single toggle |
| Compressive Strength (feed) | ≤100 MPa |
| Sealed Structure | Fully enclosed dust-proof body |
Capacity may vary depending on material type, moisture content, and discharge setting. It is recommended to conduct a pilot test for non-standard materials.
Why Choose This Product
- Proven Reliability: Our sealed jaw crusher has been field-tested in the world's toughest mining and industrial labs for over two decades. The heavy-duty frame and oversized bearings are engineered to withstand the constant shock loads of continuous crushing without misalignment or premature wear.
- Precision Engineering: Every component is machined to tight tolerances on CNC equipment, ensuring that the eccentric shaft, toggle plate, and jaw plates operate in perfect synergy. This precision translates into consistently uniform particle output, run after run.
- Enhanced Safety and Compliance: The fully enclosed body not only meets modern occupational health standards for dust exposure but also includes safety interlocks that prevent operation when the hopper lid is open. Electrical components are IP55 rated, allowing hosing down during cleaning cycles.
- Customization Capabilities: Beyond the standard configuration, we offer jaw plates in various materials for specific abrasion or contamination requirements, alternative motor specifications, and even integration with existing sample handling automation. Our engineers work closely with your team to tailor the unit to your workflow.
- Responsive Global Support: With a multilingual technical support team and a comprehensive spare parts inventory, we provide rapid on-site or remote assistance to minimize downtime. Installation and commissioning can be arranged on-site, along with operator training.
- Long-Term Investment Protection: The modular design allows easy replacement of wear parts, and the robust build ensures a depreciation life exceeding 15 years in most laboratory settings. Choosing this crusher means choosing a lasting partner for sample preparation.
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