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Compared with traditional vertical crushing systems, this structure reduces the equipment footprint by 40% and eliminates the need for additional foundation construction.
The modular assembly of the equipment supports rapid deployment, with the on-site installation period shortened to within 7 days, making it particularly suitable for mobile operations in open-pit mines.
The horizontal material flow design also reduces the material drop height, decreases the amount of dust generation, and keeps the dust concentration at the working point below 20mg/m³.
How Feeder Breakers Work?
The Working Principle Of The Continuous Crusher Follows A Sequential Process:
Firstly, the materials (such as raw coal) are unloaded into the feeding hopper of the equipment. Subsequently, the activated drive mechanism drives the scraper chain, causing it to move horizontally within the conveying box, thus uniformly transporting the materials.
When the materials reach the crushing box, they encounter the high-speed rotating crushing tooth rollers. Larger particles cannot pass through the gap between the tooth rollers and the bottom plate, and will be subjected to the impact, shearing and compression by the tooth rollers until they are crushed to the specified size.
Finally, the materials meeting the required particle size are discharged from the discharge port, completing the entire crushing process.
Feeder Breakers Unique Advantages
Compared with other brands of feeder breakers, our feeder breakers have the function of pre-screening and optional crushing form.
01/Pre-Screening
Dynamic And Static Pre-Screening
Pre-screening consists of two methods: dynamic pre-screening and static pre-screening, which are configured according to different working conditions.
Benefits
The material receiving section adopts static screening method, the static screening grate is fixed on the conveyor box by the rail, which is suitable for the screening of large particle materials.
The non-material receiving section adopts dynamic screening method. Integrate a specially designed sinusoidal disturbance screen on the conveyor box, which is suitable for screening small particles and sticky materials. The non-receiving section adopts sinusoidal disturbance screening method to prevent any material from getting stuck.
The material is pre-screened and then crushed, which can avoid excessive crushing and reduce the production of powder, maximize the yield of mineral blocks, and improve the economic benefits and value of end users.
02/Crushing Unit
Teeth Roller Crusher
Powerful function Crushing Roll(picks) with picks and a pick pattern designed for chain conveyors to crush material to the desired output size. Since the material is broken, not squashed, the lumps are consistent, producing less waste material and maximizing product value.
Benefits
The crushing teeth are made of special formula materials after precision casting and heat treatment, with high strength, wear resistance and impact resistance.
The crushing teeth adopt high frequency heating assembly, the structure is firm, reliable and durable.
Unique and novel tooth design structure, deep spiral distribution, strong biting capacity, high production efficiency.
The Hammer crusher is connected to the motor by the triangular belt. The height of the Hammer crusher can be quickly adjusted by means of a hydraulic device to adjust the discharge size of the crushed material in order to meet the needs of different customers.
Benefits
The modular design of the tooth head is fixed to the crushing hammer by high-strength bolts, enable the targeted and efficient replacement of individual tooth head.
The crushing method using a breaker hammer has a significant effect on the presence of ultra-large pieces of materials in open-pit mines.
Hammer crusher is a new type of crusher developed for large particle size materials, with wear-resistant, large processing capacity, long service life and so on.
Feeder Breakers Details
Crusher Parts
Teeth Roller (Picks)
The crushing teeth are made of special formula materials after precision casting and heat treatment, with high strength, wear resistance and impact resistance.
The crushing teeth adopt special installation technology and design structure: adopt high frequency heating assembly, the structure is firm, reliable and durable. Unique and novel tooth design structure, deep spiral distribution, strong biting capacity, high production efficiency.
Hammer Crusher (Picks)
The hammer crushing tooth head are fixed by the way of movable teeth head, which is easy to replace and reduce loss. The crushing method using a breaker hammer has a significant effect on the presence of ultra-large pieces of materials in open-pit mines.
Conveyor Parts
Drive Device
Our drive system utilizes an AC variable frequency drive system that integrates software with electronic and mechanical systems to provide precise conveyor speed control and overload protection.
Chain
Employing a combination of high-strength mining-grade round link chains and connecting rings, this system boasts superior tensile strength and wear resistance, specifically designed for continuous heavy-duty operation. Its unique quick-connect structure simplifies maintenance and replacement, significantly reducing downtime and ensuring consistently stable power transmission throughout the crushing production line.
Scraper
The scraper blades, made of high-performance alloy steel, combine high strength, impact resistance, and a compact design. The optimized installation structure facilitates maintenance, effectively resists impacts from large materials, keeps the conveyor platform clean and unobstructed, and significantly improves overall machine efficiency and service life.
Sprocket & Shafts Assembly
The Head/Tail Shafts are designed for disassembling maintenance as a whole unit. Shafts designed with alloy hardened, tempered and stress relieved steel. Sprockets are designed with either sheet flame hardened steel or split steel to provide additional maintenance options.
Tension Device
There is a hydraulic adjustment device at the tail of conveyor body, and the manual hydraulic pump adjustment device can realize that even if the feeding end of the machine is buried in the "material", it can also quickly adjust the chain tightness to ensure the equipment stable operation.
Conveyor Box
The Conveyor box consists of a number of small Conveyor boxes connected by high-strength bolts in a row, the main function is to connect the head and tail and carry the conveyor chain sliding in it to transport materials. The Conveyor box is welded by high strength wear-resistant steel plate, strong structure and beautiful appearance. The inner liner plate is made of wear-resistant plate and connected by bolts, making it easy to replace.
Feeder Breakers Features
01/ Horizontal Integration
Adopting a unique "conveying-crushing-discharging" horizontal integrated design, it integrates the processes that would typically require multiple equipment in the traditional process into one unit. This not only significantly reduces the equipment footprint and construction costs, but also fundamentally lowers the drop and blockage risks in material transportation by creating a continuous and stable horizontal material flow. The system layout is extremely simple and efficient.
02/ Powerful Rock Breaking
The core crushing component adopts a heavy hammer with large teeth design. It uses the combined effect of shear force and tensile force to break the materials, achieving efficiency far exceeding that of either impact or compression crushing alone. This principle is particularly suitable for the characteristics of materials such as coal and gangue, enabling efficient crushing while effectively reducing energy consumption and over-crushing phenomena, and significantly increasing the output rate of lump coal.
03/ Super Strong Body
The entire machine body is made of heavy-duty steel structure. The key load-bearing parts have been optimized with reinforcing ribs, and the plate thickness reaches up to 40mm. The conveying trough is composed of Q355B steel and NM400 high-strength wear-resistant lining plates, which can easily withstand direct impacts from materials up to 1000mm in size and continuous loads of up to 300 tons per hour, ensuring the long-term stability of the equipment under extremely harsh working conditions.
04/ Wear-resistant Design
In the face of harsh abrasive environments, the equipment adopts modular wear-resistant designs at key wear-prone areas. The bottom liner of the conveying trough, the crushing teeth head, etc., are all made of high-strength wear-resistant materials and connected by bolts. This not only ensures excellent wear resistance but also provides great convenience for quick replacement and maintenance in the future, effectively extending the service life of the entire machine.
05/ Rapid Relocation
Thanks to its highly modular design, the equipment can be disassembled into several standard modules. The maximum single-piece weight is strictly controlled, making it highly suitable for the frequent relocation required in mining pits. Compared to fixed crushing stations, it can closely follow the advancing mining face, significantly reducing the distance for truck transportation and effectively lowering operating costs.
06/ Closed Operation, Environmentally Friendly And Clean
The entire machine adopts a fully enclosed structural design. The materials are transported and crushed within the enclosed box. This effectively prevents dust from escaping at the source. Standard dust collection interfaces are reserved at the top of the equipment, which can be conveniently connected to bag-type dust collectors or spray dust suppression systems to ensure that the working site meets strict environmental protection emission standards.
Submit your requirements and talk with one of our technical engineer about your project.
Feeder Breakers Brochure Download
Manufacturing Facilities
A high quality mechanical products, must have excellent tooling equipment. In order to ensure its accuracy and meet the needs of large orders. Henan Excellent Machinery Co.,Ltd owns 140 sets of professional equipment, including Five-axis Gantry Machining-center, CNC Boring And Milling Machining Center, Vertical Machining Center, Vertical CNC Machining Center, Gantry Machining Center, Laser Cutting Machine, Laser Pipe Cutting Machine, Welding Robot Workstation, Lengthen Lathe, CNC Horizontal Machining Center, etc. Advanced processing and manufacturing equipment including Environmental Spraying Room and Heat Trea equipment and ultra large Surface Heat Treatment.
Strict Quality Control
At present, EXCT has fully passed ISO9001-2008 international quality system certification, complete quality system make sure that from the product development and design, production, procurement and supply to sales and service process has been effective quality controlled.
EXCT has a rigorous and skilled inspection team to ensure the success of product quality control. The quality inspection department has a strict testing process that runs through the stages of raw material procurement, production, and installation to ensure that every piece of equipment delivered to customers is qualified.
Feeder Breakers Cases
Feeder Breakers is mainly used in raw coal crushing, raw ore crushing and other industries. Widely used in coal, Lignite, salt, Gypsum, limestone, Shale, Potash, and so on.
Submit your requirements and talk with one of our technical engineer about your project.
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General Technical Specifications
EXCT Feeder Breakers are customized for each application material to provide the best configuration and meet all your requirements. For more configurations please contact our technical engineers.
| Equipment Model | Conveyor Width(mm) | Conveyor Length(m) | Max.Material Input Size(mm) | Nominal Material Output Size(mm) | Handling Capacity(t/h) |
| TP1400 | 1,350 | 6-20 | 800×800 | ≤200 | 500-1,000 |
| TP1600 | 1,550 | 8-25 | 1,000×1,000 | ≤300 | 800-1,400 |
| TP1800 | 1,750 | 8-30 | 1,200×1,200 | ≤300 | 1,200-2,000 |
| TP2200 | 2,150 | 8-30 | 1,500×1,500 | ≤400 | 1,500-3,000 |
| TP2400 | 2350 | 10-30 | 1,750×1,750 | ≤500 | 2,000-4,000 |
| TP2800 | 2750 | 10-30 | 2,050×2,050 | ≤500 | 3,000-5,000 |
* The above technical specifications are for reference only, we can also provide customized solutions according to customer requirements.
Selection Instruction
1.Which material to be crushed:______
2.Handling capacity:______t/h.
3.Bulk material density: ______t/m3
4.The material compressive strength:______Mpa
5.The material HGI (hardgrove grindability index) range:____
6.Material particle distribution percentage?____
7.Max. material size input: ______mm
8.Material size output:____mm
9.According to your actual application,the length of scraper conveyor you required:___m
10. Is the layout of the Feeder Breakers inclined or horizontal ? If it is inclined,what is the inclined degree______°
11.What equipment is used to feed the material into the feeder breaker?
12.What equipment is used to discharge the material from the feeder breaker?
13.Working power supply: ______ V ______ HZ
Feeder Breakers Spare Parts
Combines NarrowV-Belt
Replaceable Toothed Head
Heavy Duty Scraper
Tail Sprocket Assembly
Feeder Breakers Service
Project Feasibility Report
Site Design and Planning
Model Selection and Proposal
Model Selection Calculation
3D Modeling and Drawings
Civil Design
Installation and Commissioning
Remote Diagnosis
Training Service
Maintenance Schedule
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