MASTER YOUR OUTPUT

CRUSHER SELECTION QUICK GUIDE

CRUSHER SELECTION
QUICK GUIDE

A CHOICE FOR TODAY AND TOMORROW

A crusher is a major investment, so its essential to select one with the potential to meet your needs
into the future. This guide covers a few of the key points to consider before making a decision.
But remember that your crusher is just one part of a wider process always consider crushing in
conjunction with screening and transport.

THE PROCESS WHAT AND WHEN

A PPL

IC

ATIO
Prim
N
ar y c
r
u
mtrl.
abov shing, bla
e 80
0 m t s te d , a b r
ph 1
asive
Prim
.5
ar
mtrl. y cr ushin
belo
g
w 80 , blasted
0 mt
ph 1 , abrasiv
Prim
e
.5
ar
non - y cr ushin
abra
g, bla
sive
mtrl. sted,
1.6
Se co
ndar
y cr u
shing
, abra
Se co
sive
n
mtrl.
mtrl. dar y cr us
2.5
(Lim
h
ing, n
e s to
on -a
n e)
bras
2.6
Fine
ive
cr
abra ushing, m
sive
mtrl. a ximize
fines
3.5.7
,
Fine
cr us
hing
non ,m
abra
sive a ximize
fin
mtrl.
3.6.7 es,
Fine
cr us
hing
- Mo
ist an
d stic
Fine
k y fe
cr us
ed 3
h
ing, lo
fines
in pr
w
amo
od uc
u nt o
t.
f
Man
ufac
t u re d
sand
, abra
sive
Man
mtrl.
ufac
tur
1.4
non abra ed s and,
sive
mtrl.
2. 4
Cubic
izing
, abra
sive
mtrl.
Cr u s
1
hing
fe
amo
unt o r ro -alloy
s
f 0 -X
mm , minimiz
7
e

The first considerations are at what point in the process the crusher will be used, the type of
material, and the output required. Use the table below as a guide.

MACHINE
Primary Gyratory
Crusher

Primary Jaw
Crusher

Primary HSI
Impact Crushers

Secondary Cone
Crushers S-type

Secondary HSI
Impact Crushers

Cone Crushers
H-type

Impact Crushers
- VSI

P
B

Recommendations: Good (G) , Best (B), Possible (P)

1. A typical example of primary crushing is reducing

topsize from 900 to 300 mm.

5. Typical abrasive rocks are Granite, Quartzite, Diorite,

Trap rock, Basalt, Gneiss - Abrasion index above 0.10

2. A typical example of secondary crushing is reducing

topsize from 300 to 100 mm.

6. Typical non-abrasive rock is clean Limestone (Marble) -

Abrasion Index below 0.10

3. A typical example of fine crushing is producing concrete

aggregates in fractions below 30 mm.

7. Fines or 0-X mm material is normally below 2 mm.

-0.075 mm is called filler

4. Manufactured sand is typically smaller than 5

(often 2) mm.

CRUSHER SELECTION
QUICK GUIDE

WHICH CRUSHER DESIGN?

Is it a heavy duty application with a lot of wear and
tear? Consider whether you need top and bottom
mounted rather than bottom only.

Top and bottom mounting increases robustness.

The spindle principle can be illustrated as above.

WHICH CHAMBER?
Different materials and outputs demand
different crushing chamber designs. Dont
accept close enough select a supplier with
the right match.

Extra coarse

Medium

Gain with CLP

(Constant Liner Performance)

160

CAPACIT Y (TONNES/HR)

Medium fine

Fine

Extra fine

Capacity and reduction ratio can decrease with

mantle wear. For consistent production, choose a
crusher with a design that delivers constant liner
performance through the entire product lifetime.

Spider
design

100

Medium coarse

MAINTAINING OUTPUT
OVER TIME

140
120

Coarse

80
60
Traditional crushing
chamber design

40
20
0

100

200

300

400

500

600

700

OPERATING HOURS

AUTOMATE!
PRODUCTIVITY

Modern automation systems constantly

adjust the CSS (Closed Side Setting)
with no need to shut the machine down.
Compensates for variations in feed
material and wear in wear parts.

TIME
Lost production

Manual calibration

Automatic calibration

CRUSHER SELECTION
QUICK GUIDE

PLAN YOUR OUTPUT

You can only choose the right crusher if you know exactly what you want to achieve.
Overall profitability depends on the balance between fractions and fines.
Consider this:
Higher quality means more fines what balance will give you the best total result?
Production time, energy costs and wear and tear from recirculation all affect
your bottom line.

INCREASE REDUCTION OR REDUCE FINES

CONSIDER YOUR OPTIMAL OUTPUT
To illustrate the benefits of optimising your set-up, we compare Sandviks
CH540 and CH430 crushers.
Additional sales generated by the CH540:
26 mtph x 1500 h/year x 8 Euro/ton = 312,000/year

The bottom line:

Fast ROI and a significant increase in sales.

Additional cost CH540 vs. CH430:

Investment cost approx. 40,000
Cost wear and tear approx. 10,000
Energy cost approx. 10,000*

*Annual cost based on Swedish prices

Feed 545 mm

CH430

Feed 545 mm

75 mtph

101 mtph

81 mtph

105 mtph

CH540

Net cap. 75 mtph

Net cap. 101 mtph

Throw: 34 mm

Throw: 48 mm

CSS: 9 mm

CSS: 10 mm

80% < CSS

91% < CSS

73% < 8 mm

78% < 8 mm

92% < 11.2 mm

81 mtph

0 mtph

0 mtph

97% < 11.2 mm

105 mtph

Reduction: 3.7

Reduction: 4.2
No plastic backing
6 mtph

3 mtph
81 mtph

105 mtph

16 mtph

19 mtph
59 mtph

27 mtph

13 mtph

19 mtph

82 mtph

26 mtph

19 mtph

37 mtph

16 mtph

27 mtph

13 mtph

19 mtph

26 mtph

19 mtph

37 mtph

19 mtph

Stockpile
8.011.2 mm

Stockpile
4.08.0 mm

Stockpile
2.04.0 mm

Stockpile
02.0 mm

Stockpile
02.0 mm

Stockpile
2.04.0 mm

Stockpile
4.08.0 mm

Stockpile
8.011.2 mm

CRUSHER SELECTION
QUICK GUIDE

DONT MISS HIDDEN COSTS

Time spent on changing parts during service and
maintenance, and the number of people it takes,
also affect profitability. Premium machines are often
designed for easy fitting and maintenance, saving
time and costs.
Energy use is also an important factor new
crushers should be equipped with IE3 motors.

A mantle lifting devices is one

way to save time and increase safety.

PROFITABLE QUARRYING:
GET THE BIG PICTURE
Great athletes never stop striving to get closer to perfection. Neither do we. We
believe that there is always room for improvement a tweak here and a tweak there.
Weve always been driven to make better and better equipment. But today, we make
an even bigger difference by understanding how the entire process works together.
Time to take a fresh look at your quarry or mobile crusher operation?
Contact your local representative or visit construction.sandvik.com.