Regardless if you operate a bucket crusher attachment, a small jaw crusher, or a compact crusher. Every machine has its limits and there is the right crusher for every job. If you don't know the limits of your small crusher you are bleeding money to downtime and high repair costs. The good news is that you don't have to run into those issues if you consider the following candid points.
1. Trying to do large crushing jobs with a small crusher
You can always do a small job with a large machine but the other way around is difficult. Trying to do a large job with a small crusher will take forever because you are limited with the overall capacity of your small crusher but also the prep takes longer when you need to prep Vollkswagen size concrete slabs down to 15" and smaller pieces with a hydraulic hammer or concrete pulverizer.
Let's compare a 2,000 ton concrete job with rebar to be done with a small jaw crusher and an impact style comapct crusher.
|Small Jaw Crusher||Compact Impact Crusher|
|Production capacity (3" non-spec)||50 TPH||100 TPH|
|Time to produce 2,000 tons||40 hours (6 days)||20 hours (23 days)|
|Material feed size||15"||18"|
|Time to prep material (assuming 1 days of crushing = 1 day of prep )||48 hours||24 hours|
|Total excavator time needed for prep+feed||88 hours||44 hours|
|Feed tool||15 ton excavator||20 ton excavator|
|Cost to rent excavator incl operator||100 $ / hour||120 $ / hour|
|Total cost to feed the cruhser||$8,800||$5,280|
The cost to get the material phsyically through the small crusher outweighs the savings in mobilization or wear (jaw vs impact crusher). Using the right size machine gives you back valuable time to make money on other projects. The same hold true for trying to do a 300,000 tons job with a Compact Crusher. At this point you definetly want to consider a crushing spread over an individual mobile unit.
2. Failing to prep material before crushing
Crushing is all about material prep and logistics. If you can't feed your crusher constantly, you are losing production and you start losing money to interruptions as a result of blockages. A constant feed ensures a smooth and even wear pattern and maximizes rock-on-rock crushing.
There are several ways to prepare materials for your crusher
- Hydraulic hammers are ideal for sizing and breaking rock
- Mechanical pulverizers can be utilized to prep a concrete pile with lots of flatwork
- Hydraulic pulverizers are good for demolition and concrete with lots of rebar
- Adjusting the blast pattern that yields smaller rocks
- Using a primary jaw crusher to reduce the amount of prep necessary
- Asphalt can be broken up with a bucket
If you can't prep the material it is recommended to set oversize pieces aside.
3. Flip-flopping operators
Event though small crushers are often simpler than its bigger counterparts operators have to know the equipment because a crusher can't be feed like a dump truck. Operators can make or break your crushing operation. If you put different operatos on the machine you risk damages and can't get the most out of your machine. Trained operators will know your small crusher and listen for unusual noises and watch out for problematic feed material before it enters the crusher.
Check out our crusher operator job descirption template to hire a crusher operator.
RUBBLE MASTER compact crushers are delivered with an on-site start-up training so that you get the most out of your machine.
4. Renting your small crusher without your operator
Even worse than flip-flopping operators is renting out your small crusher without your operator. It is tempting to loan your machine because the demand is high and there are many contractors out there who need just a small pile crushed. However, untrained operators can wreck your machine instantaneously - especially with a sentiment of "drive it like a rental car."
5. Using accessible platforms and conveyors as picking points for trash
It is tempting to have a ground laborer pick trash from conveyor belts and service platforms because everything is easily accessible on a small crusher. However, crushing is a violent process and can cause accidents with severe bodily injuries. Your limbs can get caught in conveyor belts and ricocheting rocks can take out your eyesight. If you allow ground guys to be on top of machines or pick material from conveyor belts or screen boxes while running you risk their safety. Start-up training on new machines will educate you on the safety features. If you have a new crew and require training you can book an on-site operator training.
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