Considering whether to upgrade to larger, more modern machinery due to a new project or an increase in material availability during the dryer months?

For crushers and screens, the choice largely depends on what you are crushing or processing and the intended final product. Selecting the right type of crusher is essential for your application to ensure high efficiency and minimize operational costs.

Important factors to consider include:  

The final shape of the product  

• The shape of the particles, whether cubical or angular, is a key factor in selecting the appropriate crusher. Cone and compression crushers primarily produce more angular particles, whereas impact crushers tend to create more cubical particles.

The feed size of the material and desired output  

• The dimensions of the largest particles in the feed materials dictate the required inlet opening, the suitable type of crusher and how many crushing stages.  

• The relationship between the feed size and the desired output size influences the choice of crusher and the number of crushing stages needed to reach the target dimensions. For instance, cone crushers can generate finer product sizes than jaw crushers.  

• The potential for additional screening or classification equipment, primarily depends on the required particle size distribution

The hardness, abrasiveness, moisture content and stickiness of the rock  

• The hardness of a material plays a crucial role in determining the necessary crushing force and the appropriate type of crusher to use. For harder materials, compression crushers may be required, whereas softer materials can be effectively processed using impact or roller crushers.

• Highly abrasive materials can cause significant wear on crushing surfaces, influencing both the selection of the crusher and the choice of wear-resistant components such as liners, blow bars etc.

• The moisture level of the material can significantly affect the crushing process and dictate the type of crusher used. Certain crushers, like jaw crushers are capable of managing higher moisture content.

• Sticky materials, particularly those with high clay content, can lead to problems like blinding mesh and blockages. To mitigate these challenges, consider using specific accessories such as various screen media types, declogging rods, finger decks and equipment like trommels to resolve many of these issues.

Tonnage demands

• The required production capacity, expressed in tonnes per hour, determines the appropriate size and type of crusher. If the desired output exceeds a certain level, it may be necessary to utilize a larger crusher or implement multiple crushing units

Operational costs

• The ongoing expenses, including fuel consumption, employee wages, parts replacement, and maintenance and more play a crucial role in any project, and the selection of the crushers and related equipment can have a huge impact on this

• Onetrak can help you determine your best estimate on the overall costs for a project

Knowledge on running the plant

• Jaw Crushers perform optimally when the entire crushing chamber is utilized for reducing material size. To achieve this, ensure that the Jaw Crusher is choke-fed, keeping the crushing chamber at 50-80% full. This practice aids in pulling the material down into the chamber, enhances the shape of the material, and boosts overall efficiency. Cone crushers also run smoother, more efficiently, have a more even liner wear and have better shaped product if also choke fed.

• A slower crusher speed generally benefits coarse crushing applications, leading to higher capacity and a coarser output gradation. Conversely, higher revolutions per minute is advantageous for fine crushing applications, as it keeps material in the crushing chamber for a longer duration; this results in reduced capacity, and a finer output gradation. While each liner configuration is intended to function at a suggested speed, actual material conditions may occasionally necessitate deviations from this guideline.  

• If selecting the appropriate crusher is the first major decision, the second crucial choice is determining the right wear liners to maximize the performance of the crusher. Many producers tend to reorder the same liners that were included with their initial purchase, often overlooking the fact that liners significantly impact the overall efficiency of crushing equipment and can greatly influence profitability. By optimizing the liner profile, you can enhance both the quality and size of the final product, enabling the crusher to operate more efficiently

• The screen media you choose can make a significant difference to how well your machines perform. They can determine if you meet specifications and how quickly you can produce the required quantities. It can also reduce OHS risks and effect your bottom line. Take the time to investigate thoroughly the best screen media for your application - it's worth the effort.

• Other options to consider are magnets, larger hoppers, and grizzly bars.

Footprint and plant layout

• The overall design of the crushing circuit layout, including the number of crushing stages and the arrangement of crushers, screens, and conveyors, significantly impacts the selection of crushers and the production capacity

• Onetrak has access to Aggflow technology to design your crushing circuit and forecast output.

• The available space for the working area requirements will determine the amount and size of equipment needed

Investing in the right machinery not only enhances productivity but also ensures safety and reduces downtime. Our cutting-edge technology and expert consultation services are designed to help you achieve your business goals, whether you're scaling up permanently or exploring new opportunities.

Whether you're expanding your operations or seeking a temporary boost in capacity, our RENTAL FLEET provides flexibility without the long-term commitment. Our dedicated support team is ready to assist you in selecting the right equipment to meet your specific needs, ensuring optimal performance and efficiency.

Together, we can pave the way for your success in the ever-evolving industry landscape.

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