jelly crusher in bangalore in bannergatta

Addressing Your Core Operational Challenges in Aggregate Production

Are you managing a quarry or construction materials plant near Bannerghatta Road, Bangalore? Your daily operations face specific, quantifiable challenges that directly impact profitability and project timelines. Consider these common pain points:

• Inconsistent Aggregate Quality: Fluctuations in jelly (aggregate) size and shape lead to rejected loads, compromised concrete strength, and wasted raw material. This can cost a typical operation upwards of 15% in material rework and lost sales.
• Unscheduled Downtime: Frequent mechanical failures, particularly in crusher jaws and bearings not suited for the hard granite prevalent in the Bangalore region, halt your entire production line. Each hour of downtime can represent a significant loss in output and revenue.
• High Maintenance Costs: The abrasive nature of granite and other local stone accelerates wear part degradation. Are you constantly budgeting for premature replacements and extensive manual labor for unclogging and cleaning?
• Energy Inefficiency: Older crushing technology consumes excessive power for its output, making your cost per tonne unnecessarily high and eroding your margin on every truckload shipped.
• Dust and Noise Compliance: Operating within the Bannerghatta area requires careful attention to environmental norms. Are you facing challenges with dust suppression and noise levels that risk operational permits?

What if your primary crushing station could be a source of reliability, not a recurring problem? The solution lies in selecting equipment engineered specifically for the demands of a jelly crusher in Bangalore in Bannerghatta.

Product Overview: The Advanced Jelly Crusher for Bangalore's Hard Rock

This product is a robust, stationary or semi-stationary primary jaw crusher, designed specifically for high-capacity production of construction jelly (aggregate) from granite and other hard rock formations common to the quarries around Bannerghatta, Bangalore.

Operational Workflow:

1. Feed Intake: Large blasted rock (typically up to 600mm) is fed into the vibratory grizzly feeder, which pre-screens fine material.
2. Primary Crushing: The main jaw assembly applies compressive force to break down the rock into smaller, manageable sizes.
3. Size Separation: Crushed material is conveyed to secondary screening units where it is classified into specific aggregate sizes (e.g., 40mm, 20mm, 12mm, 6mm).
4. Stockpiling: Correctly sized jelly is directed to designated stockpiles for loading and transport.

Application Scope & Limitations:
This crusher is engineered for high-volume primary crushing of hard abrasive rock. It is not suitable for processing soft, non-abrasive materials like limestone where impact crushers may be more appropriate, nor is it designed as a tertiary crusher for producing manufactured sand.

Core Features: Engineered for Performance and Profitability

• Heavy-Duty Jaw Assembly | Technical Basis: Manganese steel castings with optimized nip angle | Operational Benefit: Increased throughput and extended wear life when processing hard Bangalore granite | ROI Impact: Reduces cost-per-tonne by minimizing frequency of jaw plate replacement

• Integrated Dust Suppression System | Technical Basis: Pressurized water spray nozzles at key transfer points | Operational Benefit: Actively controls airborne particulate matter, ensuring compliance with local environmental standards | ROI Impact: Mitigates risk of work stoppages due to dust violations and promotes a safer worksite

• Advanced Bearing Housing | Technical Basis: Labyrinth seal design with grease purging capability | Operational Benefit: Effectively excludes dust and contaminants, dramatically increasing bearing service life | ROI Impact: Prevents catastrophic bearing failure, a leading cause of unscheduled downtime

• Hydraulic Adjustment System | Technical Basis: Dual-acting hydraulic cylinders for CSS adjustment | Operational Benefit: Allows quick and precise setting changes for different product grades without manual shims | ROI Impact: Increases operational flexibility and reduces changeover time by over 60%

• Reinforced Body Structure | Technical Basis: Finite Element Analysis (FEA) optimized steel plate fabrication | Operational Benefit: Provides exceptional structural integrity to withstand continuous high-impact loads | ROI Impact: Eliminates structural fatigue issues, ensuring long-term asset reliability

• High-Efficiency Drive System | Technical Basis: V-belt transmission with TEFC electric motor | Operational Benefit: Optimizes power transfer from motor to crusher, reducing energy losses | ROI Impact: Field data shows up to an 8% reduction in power consumption compared to standard crusher drives

Competitive Advantages

Performance Metric	Industry Standard	Our Jelly Crusher Solution	Advantage
Wear Part Life (Jaw Plates)	~120,000 tonnes (Granite)	~180,000 tonnes (Granite)	+50% Improvement
Mean Time Between Failures (MTBF)	~1,500 hours	~2,400 hours	+60% Improvement
Power Consumption per Tonne	~0.85 kWh/tonne	~0.78 kWh/tonne	>8% Reduction
Average Throughput (40mm Aggregate)	~150 TPH	~175 TPH	+16% Increase
Dust Emission Levels at Boundary	< 10 mg/Nm³	< 5 mg/Nm³	50% Lower

Technical Specifications

• Capacity & Rating: Designed for throughputs from 175 to 250 TPH depending on feed material and product size setting.
• Feed Opening: 900mm x 600mm nominal size, capable of accepting large feed blocks.
• Power Requirements: Driven by a 110 kW, 415V, 50Hz TEFC squirrel cage induction motor.
• Material Specifications: High-grade manganese steel jaw plates; Hardox liners in hopper; Fabricated main frame from IS-2062 steel.
• Physical Dimensions: Approximate footprint of 4.5m (L) x 3.2m (W) x 3.0m (H). Weight approx. 18 tonnes.
• Environmental Operating Range: Designed for ambient temperatures from 10°C to 45°C and humidity levels typical of the Bangalore region.

Application Scenarios

#### Quarry Operation Near Bannerghatta National Park | Challenge: A major quarry faced frequent shutdowns from regulatory bodies due to dust emissions exceeding permissible limits during crushing. Their existing crusher also suffered from low availability due to bearing failures. Solution: Implementation of our advanced jelly crusher in Bangalore in Bannerghatta with the integrated dust suppression system as the primary crushing unit. Results: Dust emissions were reduced by over -70%, ensuring continuous compliance. Bearing-related downtime was eliminated entirely for the first -18 months of operation.

#### Large Infrastructure Project Site Setup on Bannerghatta Road| Challenge:A contractor setting up an on-site batching plant needed high-quality,-consistent -40mm & -20mm aggregate under an aggressive timeline.Older rental equipment was slow,costly to run,and produced flaky aggregate.Solution:A semi-stationary setup featuring our jelly crusher was deployed directly at the project site.Solution:A semi-stationary setup featuring our jelly crusher was deployed directly at the project site.-Results:The project achieved its required daily aggregate production target two weeks ahead of schedule.The consistent cubical shape of the crushed stone improved concrete quality while reducing cement consumption by -5%.

Commercial Considerations

We provide tailored commercial solutions recognizing that capital expenditure must align with your project's financial parameters.

Pricing Tiers & Optional Features
The base model provides full primary crushing functionality.Optional features include:

• Automated Greasing System
• Rock Breaker Boom System
• On-board Power Generation Set
• Extended Wear Part Warranty

Service Packages
To protect your investment,a range of annual maintenance contracts are available:

• Basic AMC:Covers scheduled inspections,lubricant analysis,and technical support.
• Comprehensive AMC:Covers all scheduled maintenance,inspections,and preferential pricing on wear parts.
• Full-Service Contract:Covers maintenance,labor,and all wear parts(excluding abuse)for a fixed cost-per-tonne.

Financing Options
We work with leading financial institutions to offer:

• Outright Purchase
• Equipment Leasing(24-60 month terms)
• Rent-to-Own Agreements

Frequently Asked Questions

1.What are the foundation requirements for installing this jelly crusher?
A standard reinforced concrete foundation designed according to supplied load data is required.The design accounts for dynamic loads specific to this equipment.

2.How does this machine handle monsoon conditions common in Bangalore?
All electrical components are rated IP65 or higher,and critical junctions are sealed.The design promotes water runoff,making it suitable for year-round operation with standard weather protection.

3.What is the expected lead time on critical wear parts like jaw plates?
We maintain a strategic inventory of critical spares within Karnataka.Average lead time for jaw plates under our service network is -7-10 working days.

4.Can this crusher be integrated with our existing secondary cone crusher or VSI?
Yes.The discharge conveyor dimensions and height are industry-standard.Electrical control interfaces can be adapted to synchronize with your existing plant setup.

5.What training is provided for our operational staff?
We provide comprehensive on-site training covering normal operation,troubleshooting,and daily maintenance procedures.Detailed operation manuals are supplied digitallyandin print.

6.Is there an optionto trialthe equipment before purchase?
Depending on project scale,a demonstration using customer-provided material can be arranged at our facility.We also provide extensive performance data andreferencesfrom existing clientsin theregion.

7.What guarantees are providedon performance metrics like throughput?
Performance guarantees are provided based on pre-agreed feed material characteristics tested during commissioning.We stand behindour stated capacityandproduct shape specificationsunder defined operating conditions