5 Tips for Maximizing Crusher Efficiency

1. Train Qualified Operators

One of the most reliable ways to improve crusher output is to invest in your equipment operators. Providing additional training opportunities to your team can help you increase efficiency by improving workplace safety and eliminating common process bottlenecks. 

Training can also improve staff morale and build confidence, helping to increase job satisfaction and employee retention. Through training courses, operators become well-versed in the equipment they work with each day and become more confident in their operations. Efficiency and productivity increase as a result, providing performance data that further empowers your team.

2. Use the Right Crusher for the Job

Using the wrong crusher for your application can reduce efficiency and cause downtime. For example, machines better suited for secondary crushing are incapable of handling the same type of demand that primary crushers process during normal operations.

It’s vital to understand which types of crushers are most effective for specific job types:

• Jaw crushers: Compressive force within a jaw crusher traps hard, abrasive and brittle material between two large mechanical jaws, breaking it down as a means of primary crushing.
• Gyratory crushers: The oscillating staff in a gyratory crusher provides a continuous force for effective primary crushing of large, hard rocks in mining and quarrying operations.
• Cone crushers: Medium-hard to hard materials move through a cone, which uses friction to break them down until they become small enough to drop out of the opening at the bottom. Cone crushers are best suited for secondary, tertiary or quaternary crushing.
• Roll crushers: These secondary crushers use two rotating cylindrical rotors to compress materials until they can slip through.
• Impact crushers: These crushers use impact to shatter material into small pieces, making it a suitable option for any stage of the crushing process.

If you need assistance selecting a crusher for your operations, working with an experienced sales professional who knows the specific types and models of equipment you work with can be helpful.

3. Fine-Tune Crusher Settings

Fine-tuning your crusher to match your application is essential for optimizing your output without using more resources.

Some important settings you may need to change include:

• Crusher speed: Each crusher model has an optimal speed range determined by the manufacturer. Consulting your manufacturer’s instructions can help you ensure you run your crusher at its ideal speed.
• Nip angle: With jaw crushers, the nip angle refers to the angle at which the jaws nip the incoming material. A nip angle that does not match the application can reduce capacity and cause material to slip through the jaws, increasing wear.
• Closed-side setting (CSS): The CSS is one of the most important adjustments and controls the distance between the crushing surfaces at their closest point. It influences the final particle size, producing smaller particles at finer settings.
• Feed rate: The speed at which material enters the crushing chamber can either improve efficiency by increasing throughput or decrease efficiency by raising the risk of clogging.

Note that prescreening settings can also influence efficiency. Confirm that your system is using the appropriate screen and adjust settings as needed to match your requirements.

4. Adjust Your Feed Process

The technique your operators use to feed your crusher can significantly impact its output capacity. For example, choke feeding is ideal for jaw crushers because it maximizes the amount of material in the crushing chamber at any given time. 

Additional techniques can also be used to further improve production. In-line feeding combined with the use of precrushing screens helps limit the risk of clogging the crusher by removing oversized particles and fines from the conveyor feed. 

Using a hydraulic breaker or magnet to remove as much metal as possible from the feed can also help you increase uptime by reducing the amount of metal that enters the crusher. Although jaw crushers can handle metals such as steel, limiting the amount that enters the chamber can help prevent breakage and malfunctions.

5. Follow a Preventive Maintenance Routine

Regular preventive maintenance helps maximize uptime and productivity by keeping your equipment in good operating condition. At predetermined intervals, technicians will inspect your crushing equipment and replace worn parts, restore fluid levels and clean the machinery’s interior.

Preventive maintenance works by identifying and addressing minor equipment issues before they can escalate into serious problems, which is essential for:

• Maintaining high levels of productivity.
• Creating a safer jobsite.
• Extending equipment lifespans.
• Maximizing your return on investment (ROI).

While larger businesses can often perform maintenance in-house, smaller facilities may need to work with external service providers to make sure their equipment receives the proper level of care. 

Some newer models of equipment also enable predictive maintenance, which uses a system of artificial intelligence (AI) and internet-connected sensors to monitor equipment health in real time. Rather than waiting for specific dates to discover issues, you can find and address problems right away to minimize negative impacts.

Minimize Downtime and Maximize Efficiency With Crushing Equipment Solutions^™

As a full-service crushing equipment dealer and service provider, we’re dedicated to helping our customers improve crushing efficiency using the most straightforward tools and techniques. You can find us throughout Oklahoma and Texas, with locations in Oklahoma City, Tulsa, Paradise and Taylor.

Contact us online for more information about any of our crushing products and services, or visit your nearest location to discuss your needs in person.