What is the difference between Single Toggle and Double Toggle jaw crushers?

Single Toggle jaw crushers have one toggle plate, a simpler construction, higher operating speed, and are lighter — making them ideal for mobile crushing units, medium-hard materials, and high-throughput applications. Double Toggle jaw crushers use two toggle plates, operate at lower speeds, and apply a purely compressive crushing motion with no rubbing — making them the preferred choice for extremely hard, abrasive materials like quartzite and high-silica rocks where liner wear is a critical concern. For most standard quarrying and mining applications in India, a Single Toggle jaw crusher like the GJC Series offers the best balance of productivity, maintenance cost, and versatility.

Why is my jaw crusher bearing overheating?

Bearing overheating in jaw crushers is typically caused by one of three issues: (1) Over-lubrication — too much grease causes churning friction and heat build-up; always follow the manufacturer's specified grease quantity. (2) Wrong grease type — using a grease with incorrect viscosity or temperature rating for your operating environment leads to rapid breakdown and heat. (3) Contaminated or damaged seals — dirt, dust, and water ingress accelerate bearing wear and cause overheating. Check seals regularly, especially in dusty quarry environments. Regular preventive maintenance and using the correct grade of bearing grease significantly extends bearing life in GJC Series jaw crushers.

When should I rotate or replace jaw crusher plates?

Jaw plates should be rotated when the bottom 30% of the plate shows significant wear — typically when the manganese steel teeth in the lower crushing zone begin to flatten noticeably. Rotating plates before complete wear maximises the usable life of the manganese steel and prevents damage to the jaw crusher frame. Replace plates entirely when worn below the minimum thickness specified by the manufacturer, or when you notice a consistent drop in throughput and product quality despite correct CSS settings. Monitoring wear patterns also helps identify feed distribution issues — uneven wear often signals incorrect feed size or off-centre material loading.

How do I prevent a jaw crusher from belching or popcorning?

Belching or popcorning — where rocks bounce upward out of the crushing chamber instead of being drawn in — is caused by an excessively wide nip angle or material that is too hard or too large relative to the feed opening. To prevent it: (1) Ensure feed material does not exceed 80% of the jaw gape. (2) Check that the nip angle is within the 18°–24° operating range. (3) Reduce feed rate if oversized material is entering the chamber. (4) For very hard or slabby material, consider pre-screening to remove oversized pieces. Consistent, regulated feed using a vibrating grizzly feeder virtually eliminates popcorning in most jaw crusher installations.

Crushing Equipment

GJC Series
Jaw Crusher

Q: What is the ideal nip angle for a jaw crusher?

The ideal nip angle for a jaw crusher is between 18° and 24° for primary crushing applications. This range ensures the material is gripped effectively between the fixed and moving jaw plates. If the nip angle exceeds 24°, the material tends to slip upward rather than being drawn into the crushing chamber — resulting in reduced capacity, increased wear, and inconsistent product size. At Gabbro Crusher, our GJC Series jaw crushers are designed with optimised nip angles to ensure maximum grip and throughput across all feed sizes.

Q: How does the Closed Side Setting (CSS) affect throughput and product size?

The Closed Side Setting (CSS) is the smallest gap between the jaw plates at the bottom of the crushing stroke — it directly controls your final product size. A tighter CSS produces finer output and a higher reduction ratio, but reduces total throughput in Tonnes Per Hour (TPH). A wider CSS increases capacity but produces a coarser product. For example, tightening CSS from 50mm to 25mm can increase reduction ratio significantly while reducing TPH by 20–30%. Always balance CSS against your downstream screen requirements and plant capacity targets.

Q: What is the maximum feed size for a GJC jaw crusher?

As a general rule, the maximum feed size for any jaw crusher should not exceed 80% of the gape (feed opening width) — this is known as the 80% Rule and prevents bridging and chamber jams. For GJC Series jaw crushers, maximum feed sizes range from 108mm for the GJC 1405 up to 700mm for the GJC 3632, depending on the model. Always refer to the specific model's technical datasheet for confirmed maximum feed dimensions. Exceeding recommended feed sizes causes bridging, uneven plate wear, and increased risk of mechanical damage to the frame and toggle.

Q: How does moisture content affect jaw crusher capacity?

Surface moisture on feed material has minimal effect on jaw crusher performance. However, when the internal moisture content of the material exceeds approximately 4%, particularly in clay-bearing or soft rock formations, crushed fines can begin to stick together inside the crushing chamber — a phenomenon known as pancaking or clay build-up. This progressively reduces effective chamber volume, lowers TPH significantly, and causes uneven product gradation. In high-moisture conditions, regular chamber clean-outs, wider CSS settings, and pre-drying or screening of wet clay-rich fines before the crusher feed can maintain consistent throughput.

Q: Can a jaw crusher be used for recycling concrete with rebar?

Yes, jaw crushers can process recycled concrete containing rebar — however, specific precautions are essential. A magnetic separator must be installed on the discharge conveyor to remove liberated steel rebar after crushing. Jaw plate profiles should be selected specifically for recycling duty — smooth or low-profile plates reduce the risk of rebar snagging between teeth. Feed size should be controlled to prevent large rebar loops from entering the chamber intact. With correct setup, GJC Series jaw crushers can be configured for concrete recycling applications delivering high-quality recycled aggregate for road base, backfill, and non-structural concrete use.

Jaw Crusher Manufacturer in India

Gabbro Crusher is a jaw crusher manufacturer in India specialising in primary and secondary crushing equipment for quarrying and mining operations. The GJC Series Jaw Crusher is built heavy-duty for continuous high-capacity performance — supplying quarry operators, mine owners, and infrastructure developers across India, Nepal, and Bhutan with reliable crushing solutions and low cost per tonne.

GJC Primary
Jaw Crusher

View Details →

GJC
Jaw Crusher

View Details →

GJC Secondary
Jaw Crusher

View Details →

Built to Last

Robust bolted and reinforced frame construction with premium grade components for long service life.

High Productivity

Superior material intake capacity with aggressive crushing action for maximum throughput and reduction ratio.

Simple to Operate

Designed for quick installation, easy operation, and remote monitoring with minimal operator intervention.

Low Maintenance

Safe flywheel and drive guards with easy access to wear parts, reducing downtime and operating costs significantly.

Primary Crushing

GJC Primary
Jaw Crusher

Heavy Duty Primary Stage Crusher

The GJC Primary Jaw Crusher by Gabbro Crusher is purpose-built for the most demanding primary crushing applications in mining, quarrying, and large-scale construction. Engineered with a heavy-duty reinforced frame and an optimised crushing chamber geometry, it accepts oversized raw feed material and delivers consistent, high-ratio size reduction in a single pass.

Whether processing hard granite, basalt, limestone, or river gravel, the GJC Primary delivers reliable continuous operation with minimal downtime. Its robust toggle mechanism and precision-machined jaw plates ensure uniform product size across every cycle — reducing load on downstream crushers and maximising overall plant efficiency.

As a leading jaw crusher manufacturer in India, Gabbro Crusher designs the GJC Primary for long service life with low cost per tonne — making it the preferred choice for contractors, mine operators, and quarry owners across India.

Key Advantages of GJC Primary Jaw Crusher

Accepts large feed sizes for high-volume primary crushing
Heavy-duty frame built for continuous 24/7 operation
High crushing ratio with consistent product gradation
Optimised jaw plate design for reduced wear and longer life
Low operating and maintenance costs per tonne crushed
Ideal for primary stage crushing in mining and quarry plants

Where Is GJC Primary Jaw Crusher Used?

Mining Stone Quarrying Road Construction Aggregate Production Infrastructure Projects

Get Best Price Request Brochure

Standard Jaw Crusher

GJC Jaw
Crusher

Proven Traditional Design — Reliable Performance

The GJC Jaw Crusher by Gabbro Crusher follows the proven traditional jaw crusher design — a time-tested configuration trusted across India's mining, quarrying, and aggregate industries for decades. Unlike modern integrated designs, this classic jaw crusher features a direct externally-mounted motor setup, offering simplicity, ease of maintenance, and straightforward field servicing.

Built for reliable primary crushing, the GJC Jaw Crusher delivers consistent high-ratio size reduction across a wide range of hard and abrasive materials including granite, basalt, limestone, and sandstone. Its conventional design makes it a highly practical choice for operations where simplicity, serviceability, and low maintenance cost are the top priorities.

As one of India's trusted jaw crusher manufacturers, Gabbro Crusher builds the GJC with heavy-grade steel components and reinforced frame construction — ensuring long service life even under continuous heavy-duty operation in remote quarry and mining environments.

Key Advantages of GJC Jaw Crusher

Classic proven design for reliable primary crushing
Externally mounted motor — easy access and servicing
Heavy-duty reinforced frame for continuous operation
High crushing ratio with uniform product output
Simple design reduces spare parts cost and downtime
Handles hard abrasive rock with consistent performance

Where Is GJC Jaw Crusher Used?

Stone Quarrying Mining Operations Aggregate Plants Road Construction Building Material Production

Get Best Price Request Brochure

GJC Jaw Crusher Manufacturer in India - Gabbro Crusher Traditional Design

Secondary Crushing

GJC Secondary
Jaw Crusher

Precision Secondary Stage Crusher

The GJC Secondary Jaw Crusher by Gabbro Crusher is engineered specifically for secondary crushing stages — processing pre-crushed material from a primary crusher and delivering a finer, more controlled product size for downstream operations. Designed with a tighter crushing chamber and optimised jaw geometry, it achieves higher reduction ratios at the secondary stage with exceptional size uniformity.

Where primary crushers handle raw oversized feed, the GJC Secondary excels at refining and shaping the crushed output — producing well-graded aggregate for road construction, concrete production, and railway ballast. Its robust frame and hardened jaw plates are built to handle the continuous feed loads typical of high-throughput crushing circuits.

Manufactured by Gabbro Crusher — a trusted jaw crusher manufacturer in India — the GJC Secondary is the ideal second-stage solution for quarry operators and aggregate producers looking for consistent product quality with low operating costs per tonne.

Key Advantages of GJC Secondary Jaw Crusher

Optimised for secondary stage crushing in crushing circuits
Tighter crushing chamber for finer, uniform product size
Higher reduction ratio than primary jaw crushers
Hardened jaw plates for extended wear life
Low maintenance design reduces operational downtime
Ideal for producing well-graded aggregate and ballast

Where Is GJC Secondary Jaw Crusher Used?

Aggregate Production Road Construction Concrete Manufacturing Railway Ballast Stone Crushing Plants

Get Best Price Request Brochure

Technical Data

GJC Jaw Crusher
Technical Specifications

All GJC Series Jaw Crushers are manufactured to order. Specifications are subject to change without notice. Contact Gabbro Crusher for custom configurations and capacity requirements.

Model	Mouth Opening Length × Width (mm)	Max Feed Size (mm)	Power (HP)	Speed (RPM)	CSS Max (mm)	CSS Min (mm)	Production Min (TPH)	Production Max (TPH)	Weight (Ton)
GJC 1405	355 × 127	108	20	350	20	50	5	8	1.5
GJC 1606	406 × 150	130	25	350	20	65	6	10	2.5
GJC 1808	457 × 203	175	30	350	20	65	14	18	3.5
GJC 2006	508 × 152	130	40	350	20	65	15	18	4.0
GJC 2010	508 × 254	220	40	350	30	75	15	20	4.0
GJC 2206	560 × 152	130	40	350	20	65	20	25	5.0
GJC 2210	560 × 254	220	40	350	30	75	20	25	5.2
GJC 2406	610 × 152	130	40	350	20	65	20	25	5.2
GJC 2415	610 × 380	345	50	300	75	130	35	55	7.2
GJC 3006	760 × 152	130	50	350	20	65	25	30	7.0
GJC 3018	760 × 455	415	60	300	75	140	55	80	8.0
GJC 3222	813 × 560	505	75	275	75	150	80	120	12.5
GJC 3606	914 × 150	130	60	350	25	65	30	35	7.5
GJC 3624	914 × 635	575	100	275	80	150	110	130	16.5
GJC 3632	914 × 812	700	100	275	80	150	110	140	25.5
GJC 4206	1067 × 152	130	60	350	25	65	35	45	9.0
GJC 4806	1219 × 152	130	75	350	25	65	40	55	9.5
GJC 3020	762 × 508	430	75	275	75	140	50	75	10.5
GJC 3628	914 × 711	620	100	275	75	150	110	150	25.5

PROJECT SITE GALLERY

Got Questions?

Jaw Crusher
FAQs

⚙️ Technical & Design

The ideal nip angle for a jaw crusher is between 18° and 24° for primary crushing applications. This range ensures material is gripped effectively between the fixed and moving jaw plates. If the nip angle exceeds 24°, material tends to slip upward rather than being drawn into the crushing chamber — resulting in reduced capacity, increased wear, and inconsistent product size. Our GJC Series jaw crushers are designed with optimised nip angles to ensure maximum grip and throughput across all feed sizes.

The Closed Side Setting (CSS) is the smallest gap between the jaw plates at the bottom of the crushing stroke — it directly controls your final product size. A tighter CSS produces finer output and a higher reduction ratio, but reduces total throughput in Tonnes Per Hour (TPH). A wider CSS increases capacity but produces a coarser product. Tightening CSS from 50mm to 25mm can increase reduction ratio significantly while reducing TPH by 20–30%. Always balance CSS against your downstream screen requirements and plant capacity targets.

Single Toggle jaw crushers have one toggle plate, simpler construction, higher operating speed, and are lighter — ideal for mobile units, medium-hard materials, and high-throughput applications. Double Toggle jaw crushers use two toggle plates, operate at lower speeds, and apply a purely compressive crushing motion — preferred for extremely hard, abrasive materials like quartzite and high-silica rocks where liner wear is critical. For most standard quarrying and mining applications in India, a Single Toggle jaw crusher like the GJC Series offers the best balance of productivity, maintenance cost, and versatility.

🔧 Maintenance & Troubleshooting

Bearing overheating is typically caused by three issues: (1) Over-lubrication — too much grease causes churning friction and heat build-up; always follow the manufacturer's specified grease quantity. (2) Wrong grease type — using a grease with incorrect viscosity or temperature rating leads to rapid breakdown and heat. (3) Contaminated or damaged seals — dust and water ingress accelerate bearing wear. Check seals regularly, especially in dusty quarry environments. Regular preventive maintenance and using the correct grade of bearing grease significantly extends bearing life in GJC Series jaw crushers.

Rotate jaw plates when the bottom 30% of the plate shows significant wear — typically when the manganese steel teeth in the lower crushing zone begin to flatten noticeably. Rotating before complete wear maximises the usable life of the manganese steel and prevents damage to the jaw frame. Replace plates entirely when worn below minimum thickness, or when you notice consistent drops in throughput and product quality despite correct CSS settings. Uneven wear patterns often signal incorrect feed size or off-centre material loading — worth investigating before fitting new plates.

Belching or popcorning — where rocks bounce upward out of the crushing chamber — is caused by an excessively wide nip angle or oversized feed material. To prevent it: (1) Ensure feed material does not exceed 80% of the jaw gape. (2) Check that the nip angle is within the 18°–24° range. (3) Reduce feed rate if oversized material is entering the chamber. (4) For very hard or slabby material, pre-screen to remove oversized pieces. A vibrating grizzly feeder providing consistent, regulated feed virtually eliminates popcorning in most jaw crusher installations.

📈 Capacity & Feed Management

As a general rule, maximum feed size should not exceed 80% of the gape (feed opening width) — this is the 80% Rule and prevents bridging and chamber jams. For GJC Series jaw crushers, maximum feed sizes range from 108mm for the GJC 1405 up to 700mm for the GJC 3632, depending on the model. Always refer to the specific model's technical datasheet for confirmed maximum feed dimensions. Exceeding recommended feed sizes causes bridging, uneven plate wear, and increased risk of mechanical damage.

Surface moisture has minimal effect on jaw crusher performance. However, when internal moisture content exceeds approximately 4% — particularly in clay-bearing or soft rock formations — crushed fines can stick together inside the chamber, a phenomenon known as pancaking or clay build-up. This progressively reduces effective chamber volume, lowers TPH significantly, and causes uneven product gradation. In high-moisture conditions, regular chamber clean-outs, wider CSS settings, and pre-screening of wet clay-rich fines before the crusher feed can maintain consistent throughput.

Yes — jaw crushers can process recycled concrete containing rebar, but specific precautions are essential. A magnetic separator must be installed on the discharge conveyor to remove liberated steel rebar after crushing. Jaw plate profiles should be selected specifically for recycling duty — smooth or low-profile plates reduce the risk of rebar snagging between teeth. Feed size should be controlled to prevent large rebar loops from entering the chamber intact. With correct setup, GJC Series jaw crushers can be configured for concrete recycling, delivering high-quality recycled aggregate for road base, backfill, and non-structural concrete use.

About Our Jaw Crushers

Your Trusted Jaw Crusher
Manufacturer in India

As a leading jaw crusher manufacturer in India, Gabbro Crusher has been designing and supplying heavy-duty GJC Series jaw crushers since 2011 — serving quarry operators, mining companies, and infrastructure developers across West Bengal, Northeast India, Nepal, and Bhutan. Every jaw crusher we manufacture is built to handle the toughest feed materials including granite, basalt, limestone, and quartzite with consistent high-reduction performance and minimal downtime.

Our jaw crusher manufacturing facility in India produces machines across a wide capacity range — from compact primary jaw crushers for small quarries to large-scale secondary jaw crushing systems for high-throughput aggregate plants. Whether you need a jaw crusher for mining in Northeast India, a primary crusher for a stone crushing plant in Nepal, or a secondary jaw crusher for aggregate production in Bhutan — Gabbro Crusher delivers the right solution with full installation support and after-sales service.

Looking for the best jaw crusher price in India? Contact Gabbro Crusher today for a free consultation, customised plant layout, and competitive pricing on the complete GJC Series jaw crusher range. Our engineering team will help you select the right model for your feed material, required capacity, and site conditions — ensuring maximum productivity and lowest cost per tonne from day one.

GJC Series
Jaw Crusher

Jaw Crusher Manufacturer in India

GJC Primary
Jaw Crusher