SUHMAN Introduces the Dual-Core Jaw Crusher: 15:1 Reduction Ratio in a Single Pass

For two centuries the jaw crusher has earned its place through simplicity: two plates, one eccentric shaft, rock squeezed until it breaks. But almost every jaw on the market today is a compound-pendulum design, and that design carries a built-in weakness most buyers never see until they check the stockpile: the crushing work per stroke shrinks as material travels toward the discharge opening. Down at the bottom of the chamber, where the product size is actually decided, the plates barely squeeze at all.

SUHMAN's new dual-core jaw crusher attacks that weakness structurally. It adds a second, inverted swing jaw so the discharge end gets the same full stroke and force as the feed end — and the crushing ratio jumps from the usual 3–5:1 to as much as 15:1. One machine can now take run-of-mine lump down to aggregate in a single pass.

Where the conventional jaw runs out of force

In a compound-pendulum jaw, the swing plate pivots near the top of the chamber. The stroke is largest where the rock enters and decays toward the lower bearing, so a lump only gets properly broken in the upper two-thirds of its journey. By the time material slides down to the narrow end, the chamber is passing it rather than crushing it — coarse pieces slip through, and the output carries a high share of flat, oversized flakes that the screen has to reject and the conveyor has to carry back.

That is why conventional jaws are quoted with reduction ratios of 3–5:1, and why a plant that wants a fine product usually adds a cone crusher behind the jaw. The cone is not there because jaws are slow; it is there because the jaw cannot finish the job at its discharge end.

The dual-core answer: a second swing jaw at the discharge

The dual-core design arranges two nearly identical movable jaws in a rotationally symmetrical V — upright at the feed end, inverted at the discharge end — and the jaw plates themselves are identical and interchangeable. Each jaw is driven by its own eccentric shaft, so the inverted jaw delivers maximum stroke and maximum force exactly where the conventional design has none left: at the outlet.

Power reaches both jaws through belt drives that keep them moving in strict sync. Each full crushing cycle runs through three eccentric positions:

• First 90° of rotation — both jaws swing simultaneously toward the same side of the V-shaped cavity's centre line
• Next 180° — the jaws close in on the centre line together, compressing the material caught between them
• Final 90° — the pair returns to the starting position, and the crushed material falls one stage deeper into the chamber

Because both jaws advance and retreat as a pair, every lump is nipped twice per cycle — once near the feed, once near the discharge — instead of being squeezed hard once and then left to slide. That is the whole secret of the high ratio.

The TZ6510 in numbers

• Feed inlet (L×W): 650 × 1,000 mm
• Maximum feed size: 500 mm
• Discharge range: 65–185 mm, adjustable
• Capacity: 80–300 TPH, depending on material and feed rate
• Crusher power: 132 kW
• Crusher weight: 12 t (excluding motor)
• Working dimensions (L×W×H): 3,583 × 1,964 × 2,536 mm
• Reduction ratio: up to 15:1

The complete specification sheet is on the TZ6510 dual-core jaw crusher product page.

Three flows where it pays for itself

Fine aggregate below 45 mm: about 50% more finished product

Making stone under 4.5 cm is where conventional 1060 and 1160 class jaws struggle most: the weak discharge-end stroke leaves a large coarse fraction that must be re-crushed. With full crushing force across the entire lower stroke, a dual-core machine turns out roughly 50% more finished material under 4.5 cm than a conventional 1060/1160 at the same feed rate and power draw. More saleable tonnes per tonne of electricity — the effective output of the line rises without touching anything upstream.

Sand making and shaping: the cone drops out of the flow

A traditional medium-hard or hard rock sand line runs jaw crusher → cone crusher → VSI. Since the dual-core machine can take the feed from primary size straight to the VSI's window, the cone stage becomes redundant: the flow shortens to dual-core jaw → VSI. Removing the cone saves more than its purchase price — civil works, installation, the intermediate conveyors and their electrical controls all disappear with it. The line occupies less ground, and the maintenance points and wear-part list shrink accordingly.

Hard rock, road base and water-stabilized material: one machine, two stages

Granite and basalt subbase work, water-stabilized road material and crushed stone under 4 cm traditionally demand a two-stage jaw + cone combination to hit the finished rate and particle shape. With a 15:1 ratio and sustained extrusion force, the dual-core jaw reaches the same result alone. Where space is tight, budgets are lean, or the plant is mobile, one machine doing the work of two is the deciding argument.

Common questions

What does a 15:1 reduction ratio mean in practice?

It is the ratio between the largest feed lump and the finished top size. A conventional compound-pendulum jaw manages roughly 3–5:1, so it needs a second stage behind it. A dual-core machine keeps full crushing force all the way to the discharge end, so a 500 mm feed can be reduced to a fine setting in a single pass — one machine doing what traditionally took a jaw plus a cone.

Can it replace a cone crusher in every plant?

Not in every one. It covers the flows where the target is a fine aggregate below roughly 45 mm, road base and water-stabilized materials, or the crushing stage ahead of a VSI in sand making. Plants chasing very high tonnage with tight shape limits on hard rock may still justify a dedicated cone stage.

What feed materials does it handle?

The compression chamber handles abrasive hard rock — granite, basalt, river gravel — as well as limestone, construction and demolition waste, and road base production. Material enters at up to 500 mm on the TZ6510 and exits through a 65–185 mm adjustable setting.

The dual-core jaw crusher does not break rock in a new way — it just keeps breaking it all the way down, in the part of the chamber where conventional jaws give up.

For context on where the jaw sits against the other machine types, see impact crusher vs jaw crusher and cone crusher vs jaw crusher. The dual-core design is built into the SUHMAN jaw crusher range — for a specific feed, tonnage and product size, the fastest route is to send the details through the contact page.