A leading aggregate producer in Pennsylvania approached JVI Vibratory Equipment to upgrade their cone crusher operations at their limestone quarry. The challenge: replace an existing belt conveyor system feeding their cone crusher with a more efficient, lower-maintenance solution capable of handling 600 tons per hour (TPH) of limestone. In this article, we’ll explore why this aggregate yard chose to upgrade and how JVI’s center hole cone crusher feeder package delivered the performance improvements they needed.
The Challenge: Moving Beyond Feeding with Belt Conveyors
The customer’s existing belt conveyor system was feeding -3.5″ limestone into their cone crusher, but the operation faced challenges that prompted them to seek an alternative:
Limited Flexibility
The existing belt system lacked adjustable feed rate control needed to optimize crusher performance. Without the ability to fine-tune material flow rates, the operation couldn’t maximize crusher efficiency or adapt to changing material conditions.
Accessibility Issues
Performing maintenance on the cone crusher required working around the belt conveyor system, making routine crusher maintenance more complex and time-consuming.
Maintenance Intensive Operations
Belt conveyors require regular maintenance including belt replacement, roller servicing, and alignment adjustments. These maintenance requirements resulted in increased downtime and higher operational costs.
JVI’s Solution: Heavy-Duty Center Hole Cone Crusher Feeder
After reviewing the customer’s operational requirements, JVI recommended a comprehensive feeder package centered around a heavy-duty electromechanical vibratory feeder. This solution was specifically engineered to address the aggregate yard’s unique challenges while addressing the throughput rate requirement.
Key Features of the Recommended System
Robust Construction for Harsh Conditions
The feeder features mild steel construction with JVI’s standard paint specifications, designed to withstand the demanding conditions of limestone processing. The pan measures 54″ wide by 10″ tall by 133″ long to the center of the center hole discharge, with a 27″ diameter discharge opening and an overall length of approximately 167″.
Wear Protection
Understanding that limestone processing creates significant wear challenges, JVI incorporated 3/8″ thick wear liners on all walls. These abrasion-resistant liners are bolted and replaceable, ensuring extended service life and simplified maintenance procedures.
Precise Material Control
The center hole discharge design creates a 360-degree peripheral feed pattern, ensuring even material distribution into the cone crusher. This uniform feeding promotes even wear across the entire crusher, significantly extending crusher service life compared to traditional side-feeding method of conveyor belts.
Powerful, Efficient Drive System
The feeder is driven by two JVI electromechanical unbalanced motors. The motors were sized based on the weight of the feeder and the bulk density of 100-110 pounds per cubic feet (pcf) material specifications given by the customer.
Trolley System for Enhanced Accessibility
To improve the ease of performing maintenance on the cone crusher JVI recommended the inclusion of a custom trolley system.
Manual Indexing Capability
The entire feeder package is mounted on a traveling trolley system that can be manually indexed away from the cone crusher mouth during maintenance operations. This design allows maintenance crews complete access to the crusher without dismantling the feeder system.
Integrated Support Structure
The trolley package includes a traveling mild steel frame with four heavy-duty trolleys designed to mount to the customer’s I-beam structure. Clips with pull-pins lock the feeder in position above the crusher during operation, ensuring stable performance while allowing quick repositioning for maintenance.
Suspension System
JVI designed a complete suspension hardware set featuring four rigid supports. This system supports the center discharge crusher feeder from the I-beam traveling frame while maintaining proper vibration isolation.
Optimized Material Flow with Static Chutework
To ensure optimal material transition from the existing hopper into the new feeder, JVI designed integrated static chutework as part of the complete package.
Seamless Integration
The chutework includes a bolted inlet flange designed to mate perfectly with the hopper outlet flange, ensuring a dust-tight seal and smooth material transition. This pre-designed arrangement optimizes material flow while maintaining proper clearances and interface requirements.
Strategic Material Management
The static chutework feature mild steel construction with 3/8″ wear liners on back and side walls, providing protection against wear while guiding material flow.
Single Mass Design: Simplified Operations
JVI’s single mass design philosophy delivers operational advantages for the aggregate yard:
No Tuning Required
Unlike dual-mass systems that require tuning, the single mass design eliminates this requirement, reducing operational complexity and ensuring consistent performance.
Enhanced Reliability
Fewer operating components translate to higher reliability and reduced maintenance requirements. The system can operate effectively through variations in material characteristics and head load conditions.
Isolation System
Four isolation coil springs provide proper vibration isolation, protecting the supporting structure while ensuring efficient material feeding.
Technical Specifications and Performance
The recommended feeder package delivers impressive performance capabilities:
- Capacity: 600 TPH
- Material Specifications: Limestone
- Particle Size: -3.5″ particle size
- Bulk Density: 100-110 pcf
- Adjustable Decline: 0-10 degrees (or as required)
- Flow Characteristics: Handles average to free-flowing materials
Professional Installation and Startup Support
JVI’s commitment to customer success extends beyond equipment delivery. The proposal includes comprehensive onsite startup assistance featuring:
Technical Expertise
A JVI technician provides onsite startup assistance to ensure complete plant satisfaction and optimal performance from day one.
Personnel Training
Comprehensive training for the customer’s operating personnel ensures proper operation and understanding of the equipment’s capabilities.
Maintenance Planning
JVI provides detailed preventative maintenance requirements and schedules, helping the aggregate yard maximize equipment life and minimize unplanned downtime.
Project Approval and Results
After reviewing JVI’s comprehensive proposal, the customer approved the complete feeder package upgrade. Upon successful installation and commissioning, the JVI center hole cone crusher feeder delivered significant improvements to the aggregate yard’s operation:
Proven Performance Improvements
Following installation and startup, the center hole discharge design and precise feed control optimized crusher performance, delivering the efficiency gains projected during the proposal phase.
Maintenance Reduction Achieved
The elimination of the belt conveyor system has significantly reduced maintenance requirements, lowering both direct maintenance costs and associated downtime as anticipated.
Extended Crusher Service Life
The even material distribution is promoting uniform crusher wear, extending crusher service life and reducing replacement costs exactly as designed.
Enhanced Operational Flexibility
The trolley system has proven invaluable, allowing quick repositioning for crusher maintenance and minimizing downtime, improving overall plant availability.
Engineered Performance for the Aggregate Industry
The customer’s decision to upgrade from belt conveyors to JVI’s center hole cone crusher feeder package demonstrates the significant advantages of modern vibratory feeding technology. The combination of robust construction, innovative design features, and comprehensive support services delivers a solution that not only meets current operational requirements, but positions the operation for enhanced performance and reduced costs.
JVI’s approach to this project—from custom trolley systems to integrated skirtboards and professional startup support—showcases the company’s commitment to providing complete solutions rather than simply supplying equipment. For quarry operators facing similar challenges with existing belt conveyor systems, JVI’s center hole crusher feeders offer a proven path to improved efficiency, reduced maintenance, and enhanced operational flexibility.
The success of this installation reinforces JVI’s position as a leading provider of specialized vibratory equipment solutions for the aggregate processing industry, delivering engineered systems that address real-world operational challenges while providing long-term value.