The Methods of Distinguishing the Quality of Crusher Wear Parts
Optimized maintenance is a key competitive advantage for an aggregate producer. Dealing with multiple service providers and brands can become a significant risk as response times, quality and inventories vary across suppliers. For crushers, it’s the spare parts that ensure operational uptime; they enable the metso jaw crusher spares and the process to keep on going. Would it be beneficial to have one premium partner to provide parts and services for all your crushers? We say it is something to consider, but only with the right partner – here’s why.
For us, quality is not limited to parts’ features, but it means also our readiness to provide extended support when needed. Non-OEM part suppliers might have the capability to provide a certain missing part to the crusher, but is it of the right material? The exact right design? These things can’t be guaranteed, and the risk of malfunction in operation or additional servicing can start to climb if a sub-optimal supplier is used. We combined our expertise and heritage as the pioneer in many crusher technologies into a premium series of crusher parts for non-Metso Outotec crushers, the Contender? Series. These parts are made to ensure an exact fit and they can be counted on to perform.
Another thing to consider is the warranty. If the part doesn’t live up to expectations, an OEM manufacturer like Metso Outotec has a strong warranty program in place. With warranty, the risk of unplanned costs for the crusher operator is minimized, and the performance is followed up on in a timely manner. Also, a partner like us with a strong footprint and background has more capabilities available to ensure that the right part, no matter which one it is, is in-stock when needed. We have large inventories quickly accessible and are not limited to certain parts only.
One of the main advantages of centralizing the maintenance activities of multi-brand crushers, including parts and services, is cost savings. Instead of dealing with multiple interfaces, aggregate producers can have one point of contact to take care of everything. That is our mentality, to provide a partner solution to our customers instead of just parts and products. It makes the planning a lot easier and makes the service more efficient, which helps in increasing the uptime and thus – as time is money – increase the profitability.
Sometimes, it might be enough to have the part replaced with the same solution but there could still be room for improvement in terms of performance. Contender? Series spares are not limited to standard solutions as we incorporated multiple innovations in the design. In some cases, materials and safety aspects have been improved to enhance the durability and sustainability of the parts. These innovations aren’t accessible from part providers solely focused on replicating the existing ones.
For example, the enhanced spider bushings for non-Metso Outotec crushers are strengthened to have a longer than original operational life to help performance under the toughest operating conditions. Its material has a high residual value when recycled, compared to more traditional materials. Another example is the enhanced dust seal rings, which experience less wear on mating steel parts and less surface contamination from dust and particles due to the self-lubricating design and characteristics of the materials selected. We haven’t been limited to the conventional ways of doing this but have used upgraded metallurgy and for example enhanced wood materials in our design for the dust seal rings.
Sustainability should be considered in all steps of the way, from start to finish. We use certified beech from Europe as the base for our wooden components. Safety is improved by providing part features such as additional lifting lugs and also for example by providing a specialized lifting tool for Metso Outotec-made mantles for third party sandvik jaw crusher spares. Most importantly, your operations become sustainably efficient with one partner that can be trusted to be there now and also in the future.
Although crusher parts may look the same from the outside, they may be very different in terms of quality, fit or materials.
Using an incorrect part that does not perform as planned can be very costly – equipment can be damaged, the parts lifetime may be shortened or the equipment could fail, putting the safety of workers at risk.
This e-book looks at the 7 key areas you should consider when buying crusher spare parts to help you make a good decision when it comes to choosing the right supplier.
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Crushers are widely used in metallurgy, construction, mining and other industries, and wear parts play a crucial role in the crushing process. High quality wear parts help to cut costs and increase production. How can we distinguish the quality of crusher wear parts? We can start from three aspects as below,1.Appearance Quality: Checking the smoothness of the surface of the spare crusher parts, the cracks on the products, the dimension, shape and weight etc.. Each product is strictly inspected before shipping to ensure the products are in good condition to use. Gubt provides Dimension Inspection report for your review.
2.Internal Quality: Generally, GUBT detects the grain size of the crusher wear parts, chemical components, Metallographic structure, pores, etc.. The report below is Metallographic and Chemical test report for material Manganese.
3.Performance Quality: generally, performance quality refers to wear parts how long they last, and how effectively they can crush under difference circumstances (including wear resistance, heat resistance, corrosion resistance, impact resistance etc.). There are many factors affecting the quality of spare parts.1. The design of the products. When designing, the casting geometry and dimension is not only determined by the working condition and the metal materials, but we also need consider from the perspective of casting alloy and casting process characteristics to decrease the rate of scrap. 2. Casting process. Castings’ structure, weight, dimension etc. are the critical factors for castings. With these criteria, the best casting solution will be optimized (the molds, core-making method, cold iron, risers, pouring systems etc.). 3. The quality of the raw materials. The casting quality depends on the raw materials you use, including Mn material, refractory materials, fuel, molding sand, sand binder etc. If the raw material do not meet the standards, defects happen such as pores, slag inclusions, sand sticking, etc., which will affect the appearance quality and internal texture of the products, or the products will be scrapped.
Superior Industries Inc., a U.S. based manufacturer and global supplier of bulk material processing and handling systems, says it has entered into a strategic partnership with Europe's largest manufacturer of aftermarket crusher parts. For 40-plus years, CMS Cepcor has manufactured premium cone crusher spares spares for more than three dozen active and classic brands throughout Europe. The parts manufacturer recently expanded its global footprint when it launched CMS Cepcor Americas.
From its US headquarters in Pekin, Illinois, CMS Cepcor Americas will stock, sell and service aftermarket parts throughout North and South America. In addition to the greater market, they will work closely with Superior to supply crushing equipment spares to Superior's growing group of crushing dealers and customers.
"We have assembled a talented team of industry veterans who understand what it means to serve customers with high quality products backed by timely support," says Doug Parsons, the president of CMS Cepcor Americas. "Personally, my relationship with Superior goes back two decades and our trust and confidence in each other runs deep. We're excited to fill a gap in the market where customers are not being supported to the level they require."
Choosing the most appropriate profile is not simple and there are no rules, since each application has a number of different variables like feeding, opening, product needs and problems. All these will decide the type and service life of the jaw parts you are choosing.
Certain profile types decrease or increase the crusher’s hourly production. So, for the correct choice, it is necessary to have a good knowledge of crushing and to observe what happens inside the crusher’s chamber (very lamellar material, excessive humidity, fines, need of small opening, etc).
And also the stone type also decide what material you are choosing. As we all know when the same crusher deal with different type of stones, the performance and the service life of the jaw plates are different. Why? some stones are of higher grade of the hardness, some stones are of more silica inside, etc.
So to choose the right jaw plates material on different worksite is necessary.
When the wearing of the jaw crusher spares plates is severe, it is a known fact that crusher performance is not ideal, because the empty spaces between the teeth are reduced, encagement happens frequently, the crushing angle is changed or, in other words, production is affected.
This means that, a cost-benefit analysis for changing the worn symons jaw crusher spares plate should be seriously considered, because at a certain point, the difference in production justifies the investment in a new part. We have also observed users crushing even with cracked and perforated jaw plates, without carrying out the correct control and cost x production analysis.
To change the jaw plates in time is a very very important thing to do the good maintanance. And will cause to very bad effect if we don't change the jaw plates when it's time to.
Fixed jaw plate – use until wear of about 50% occurs in the lower area and make the first turn. Make the second turn when wear from 90% to 100% occurs in this new lower area. Conclude using the remaining 50% of the life cycle of this extremity.
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