Rock crushing is an important process in the construction industry because it allows for the creation of essential aggregate products as well as the reuse of materials that would otherwise be disposed of as waste. By using a rock crusher, construction companies can recycle concrete and other rubble into usable aggregate for new construction projects. This not only saves the company money but also helps to reduce the environmental impact of demolition and construction activities.
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Making the most out of your rock crushing equipment can provide you with some important benefits that can improve your productivity and overall efficiency.
What Are Rock Crushers?
Rock crushers are used to reduce the size of rocks into gravel or rock dust. Crushers can be used to reduce the size or change the form of rocks by breaking them down into smaller pieces. The different types of rock crushers are jaw crushers, gyratory crushers, cone crushers, and impact crushers.
The main types of rock crushers include:
A jaw crusher is a type of crusher, typically used as a primary crusher in mining, that breaks down large rocks into smaller rocks, gravel, or rock dust. It is composed of a crusher head, an upper part fitted with a stationary jaw and a lower part fitted with a movable jaw. The movable jaw applies pressure to the material being crushed against the stationary jaw, breaking it into pieces. Jaw crushers are versatile, produce a high-quality output, and are easy to operate and maintain.
Gyratory crushers are heavy-duty machines used for crushing large rocks into small pieces. They have a cylindrical crushing chamber with a concave or bowl liner that accelerates the feed material and helps to break the rock. Gyratory crushers are extremely durable and capable of a high level of efficiency.
Cone crushers use a cone-shaped curtain to break rocks along the crusher&#;s longest dimension. They are often used in conjunction with other types of crushers, such as jaw crushers and hammer mills, to achieve the desired size and shape of crushed material.
Impact crushers are the most commonly used type of rock crusher. These rock crushers use a metallic hammer to break rocks. Impact crushers often have the capability to break apart very strong materials relatively easily.
Benefits Of Using Rock Crushing Equipment
Rock crushing equipment has a variety of benefits that make it an important tool for many businesses. Here are five of the most important benefits of using rock crushers:
- Increased efficiency and productivity &#; When you use a rock crusher, you can crush large rocks into smaller pieces quickly and easily. This allows you to get more work done in less time, increasing your overall efficiency. In addition, if you choose the proper equipment, you will be able to complete the aggregate production process much more quickly and cost-efficiently.
- Reduced labor costs &#; With the proper rock crusher for your project&#;s needs, you can get projects done with more speed. Be sure to understand the unique needs of your project and obtain the machinery that is best suited for the job to keep labor costs down.
- Improved product quality &#; By crushing rocks into smaller pieces, you create a more uniform product that meets your exact specifications. This improves the quality of your product and helps you stand out from the competition. Certain types of rock crushers are better at handling this type of task than others.
- Improved Versatility &#; Rock crushers can be used for a variety of applications, making them versatile tools that can be effective for multiple types of uses.
- Increased Production Capacity &#; The production capacity of your business will increase when you use rock-crushing equipment. This is because the equipment will enable you to handle more rock volume quickly, which means that you can produce more in a shorter amount of time.
Get The Most Out Of Your Rock Crushing Equipment
Rock crushing equipment is important for a variety of reasons, the main one being that it can help provide construction and demolition crews with the equipment they need to get the job done. By using rock crushing equipment properly, you can make sure that you are able to get the most out of your equipment while also ensuring that your crew is safe.
There are a few things to consider when using rock crushing equipment. First, always make sure that you are using the correct size of crusher for the job. Oversized crushers can lead to premature wear and tear on the equipment, while undersized crushers may not be able to handle the task at hand.
In addition, make sure that you are using the correct type of crusher for the application. For example, a jaw crusher is best suited for hardest rocks, while a cone crusher is better suited for the less-harder rocks.
By keeping these tips in mind and understanding the benefits of utilizing rock crushing equipment, you can put these pieces of equipment to use in your operations with ease and efficiency. For more information, reach out to Mellott&#;s team of experts today at 888-801-.
Around our offices at ELRUS we often share and discuss and reminisce about the state of the industry, people we&#;ve known in the business, the successful and those that weren&#;t. We started to notice some themes in our observations that we think are important to share and discuss.
The truth is that few of us set out as young people to be in this business. Sure, some of us have a family connection that led us to this industry but for many of us in crushing and screening, a summer job led to a career. We worked in the dust, changed some screens, fixed a few belts and shovelled out a conveyor. Because we were persistent, cared and had some good ideas, we became foreman and moved up, so we could be worried about everything, not just our piece of the process. We learned the business of rocks and became &#;rock stars&#;
Another observation we came to is this is a tough business! There is no &#;Crushing University&#; or &#;Gravel College&#; to go to for a master&#;s degree in how to make big rocks into small rocks that are the right size and shape efficiently. Additionally, fewer good gravel pits and quarries make meeting increasingly more difficult specifications very difficult. It&#;s no surprise plenty of people in this business have no hair &#; we&#;re trying to make a silk purse out of a pig&#;s ear.
During our discussions we discovered some common characteristics that define the successful people in our industry &#; the ones who grew to foreman and then to manager or the contractors who grew while others failed. In our 40 years in this business, we feel the most successful people in this business share most or all of these characteristics.
1. They have robust measurement systems and use them to drive improvement
1. They have robust measurement systems and use them to drive improvement
To determine the difference between cost and price as well as knowing throughput and understanding how to improve it, you need facts from measurement systems. At a minimum, the most successful measure:
How to Select the Best Directional Drill Machines?There are many other measurements the successful track to make it easier to analyze operating practices, especially where the quality of feed is variable.
The bottom line is - good measurement systems both support and drive continual improvement of operations and drive profitability in the hands of the right people.
2. They understand that cost and price are different considerations
The price of something is measured by the dollars spent to acquire it. For example, the price of a cone plant is $750,000. Cost is measured over time or units as measures of operations. If the cone plant lasts fifteen years, its capital cost is $50,000/year. If the cone plant will produce a 1,000,000tons in a year for fifteen years, the capital cost is $0.050/ton crushed.
The price of a different cone plant may be $650,000 and it only will last twelve years and thus making its capital cost $54,167/year. If the crusher also produces 1,000,000 tons per year, it&#;s capital cost per ton is $0.054/ton crushed.
The price maybe lower, the cost/ton produced is higher as is the cost per year.
This same analysis applies to everything from the cost of a crusher to the cost of differing qualities of screen media. You name it, the rule applies. Cost is different than price and the lowest price does not equal the lowest cost/operations or cost/unit.
3. They understand throughput
Throughput is different than production per hour or per day; throughput is dollars on the ground of sellable, in-spec material at the end of a financial period (month/quarter/year).
Operation A is producing an average of 400 tons per hour when in operation. They need to move their spread five times a year and it takes four days per move, thereby losing 20 working days per year to moves.
Operation B is also producing an average of 400 tons per hour when in operation and must move their spread five times per year. Operation B can move and be crushing in two days, thereby losing 10 working days per year.
The difference per season on a ten-hour day is 40,000 tons. At $5.00 per ton, that&#;s a difference in throughput of $200,000 per year. Over the life of the spread this is significant and pure bottom line as the cost of operations per year in both situations is similar.
4. They implement good ideas
The most successful operators we see are open to ideas, open to examination of how they have their production processes set up and open to ideas around how it could be done differently. These operators are willing to listen, analyze, examine and see if their operations could be more effective.
They experiment and if it&#;s good, they adopt the idea.
An example from the field:
Crushing >12&#; rocks in a sand and gravel operation is difficult and expensive. There is also a market for >12&#; stone for flood repair and mitigation as well as landscaping. We had a client insert a primary sorter into their spread to separate the >12&#; from the jaw feed.
Over the course of two years, the revenue from the large rock more than paid for the sorter. Importantly, his cost of crushing operations came down. Lower jaw manganese wear, improved production rates led to more dollars on the ground with fewer dollars spent getting the job done.
Good ideas are easy to come by. The people that work for us always have an idea on how things could be done better, and support industries are constantly coming up with new products and services to make operations more effective. The most successful sort out the ideas that make sense, test them out to prove them out. When shown they can work, the successful get them implemented.
Getting good ideas implemented has challenges! It often means being the lone voice in the beginning, facing down habits and opinions of current operating styles and approaches. Getting buy-in from the operations team requires support from management. Sometimes a good idea is a change in operations process. But often it requires a significant investment in production variability or equipment during the implementation It takes courage to go in front of management that may be reluctant to change; for the family business, doing the preparation to face a banker to borrow the money or convince other members of the family that a new idea or different way of operating has merit.
5. They recognize the importance of the work environment
The best in the business have a safe work environment that goes above and beyond keeping the authorities happy. They strive to build workplace environment and culture where great people work safe, grow their skills and contribute to the success of the operation.
Building this workplace culture is not easy or quick and it&#;s hard to sustain. It means hiring selectively, training and developing people, being open to their ideas and recognizing that as the leader, they are always on display &#; if they act inconsistently with what they ask of their people, they lose credibility and the trust of their people. We get this sounds lofty for a gravel pit but it&#;s real.
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