Top 10 Crusher Brand & Manufacturers

What is Crusher

A crusher is a machine designed to reduce the size of large rocks, ores, and other solid materials into smaller pieces. It applies mechanical force such as compression, impact, or shear to break the material. Crushers are widely used in mining, construction, and recycling industries to prepare materials for further processing or to make them more suitable for transportation and use.

History of Crusher

• Early Crushers: The history of crushers dates back to ancient times when humans used simple tools like hammers and anvils to break stones. In the 18th and 19th centuries, with the growth of industrial activities, more formal crusher designs emerged. The first crushers were basic and mainly used in the mining industry to process ores.
• Industrial Revolution Advancements: During the Industrial Revolution, the demand for crushed materials increased significantly. This led to the development of more efficient crusher designs. Steam - powered crushers were introduced, allowing for larger - scale operations. Jaw crushers, one of the earliest types of mechanical crushers, became more refined and widely used.
• Modern Developments: In modern times, crushers have seen numerous technological improvements. The use of advanced materials in construction, such as high - strength alloys and wear - resistant steels, has enhanced their durability. Computer - aided design and control systems have enabled more precise operation and optimization of the crushing process. There are also now a wide variety of crusher types to suit different applications and materials.

Purpose of Crusher

• Mining Industry: In mining, crushers are used to break down large ores into smaller pieces for further processing. This helps in the extraction of valuable minerals. For example, in gold mining, the ore is crushed to release the gold particles, which can then be separated through other processes like leaching or flotation.
• Construction Materials: Crushers play a vital role in the production of construction materials. They are used to produce aggregates such as gravel and crushed stone for use in concrete, asphalt, and road - building. By crushing rocks to the desired size, it ensures the quality and performance of the construction materials.
• Recycling: In the recycling industry, crushers are used to reduce the size of waste materials such as concrete, bricks, and plastics. This makes it easier to recycle and reuse these materials. For instance, crushed concrete can be used as a base material for new construction or as an aggregate substitute.

Principle of Crusher

• Jaw Crusher Principle: Jaw crushers work on the principle of compression. A movable jaw and a fixed jaw form a V - shaped crushing chamber. The material is fed into the chamber and the movable jaw exerts a compressive force on the material, squeezing it against the fixed jaw. As the movable jaw moves in a reciprocating motion, the material is crushed until it is small enough to pass through the bottom opening of the chamber.
• Impact Crusher Principle: Impact crushers use the principle of impact force. The material is fed into a rotor with high - speed rotating hammers. The hammers strike the material with great force, causing it to break into smaller pieces. The material then rebounds off the crusher's anvils or other internal components, further reducing its size through multiple impacts.
• Cone Crusher Principle: Cone crushers operate based on the principle of gyrating motion. The mantle (the inner cone - shaped part) rotates eccentrically inside the concave (the outer stationary part). As the material enters the crushing chamber between the mantle and the concave, it is compressed and crushed as the mantle moves in its gyrating path. The crushed material then discharges through the bottom of the chamber.
• Roll Crusher Principle: Roll crushers have two parallel rolls that rotate towards each other. The material is fed between the rolls and is crushed by the compressive force as the rolls rotate. The gap between the rolls determines the size of the crushed material. This type of crusher is often used for materials that require a more uniform product size.

Features of Crusher

• Crushing Capacity: Crushers come in a wide range of capacities. The capacity is usually measured in terms of the amount of material that can be crushed per hour, such as tons per hour. It depends on factors like the size of the crusher, the speed of operation, and the nature of the material being crushed.
• Versatility: They can handle a variety of materials, including hard rocks, ores, soft minerals, and even some waste materials. Different crusher types are more suitable for different materials. For example, impact crushers are good for crushing materials with a relatively low abrasiveness, while cone crushers are better for hard and abrasive materials.[!--empirenews.page--]
• Reduction Ratio: The reduction ratio is an important feature. It represents the ratio of the size of the feed material to the size of the product material. A high - reduction - ratio crusher can produce a finer product from a relatively large feed material. This allows for more efficient material processing and can reduce the need for multiple stages of crushing.
• Durability and Wear Resistance: Given the abrasive nature of the materials they handle, crushers are built with durable materials and wear - resistant components. The crushing jaws, hammers, and liners are often made of high - strength alloys or special steels to withstand the impact and abrasion and have a long service life.
• Adjustability: Many crushers allow for adjustment of the crushing settings. For example, the gap between the jaws in a jaw crusher or the speed of the rotor in an impact crusher can be adjusted. This enables the operator to control the size of the final product and optimize the crushing process according to the specific requirements.

Types of Crusher

• Jaw Crusher: As mentioned earlier, it is one of the most common types. It is characterized by its simple and robust design. Jaw crushers are suitable for primary crushing and can handle large - sized feed materials. They are widely used in mining and quarrying operations for crushing hard and abrasive rocks.
• Impact Crusher: Impact crushers are known for their high - reduction - ratio capabilities. They can produce a more cubical - shaped product, which is beneficial for some applications like the production of aggregates for concrete. They are often used in secondary or tertiary crushing stages.
• Cone Crusher: Cone crushers are used for secondary and tertiary crushing of hard and medium - hard materials. They are designed to provide a more consistent product size and are often used in applications where a high - quality final product is required, such as in the production of high - grade aggregates.
• Roll Crusher: Roll crushers are ideal for materials that require a uniform product size and for crushing materials with a lower compressive strength. They are used in applications such as the production of fine - grained materials for the chemical or food industries.
• Hammer Crusher: Hammer crushers use a set of hammers attached to a rotor to impact and break the material. They are effective for crushing brittle materials and can produce a fine - grained product. They are often used in small - to - medium - sized crushing operations, such as in the recycling of construction waste.

Precautions for using Crusher

• Operator Training: The operator of a crusher must be properly trained. Training should cover the operation of the crusher's controls, understanding of the crushing process, safety procedures, and how to handle different materials. Only trained personnel should operate the crusher to ensure safe and efficient operation.
• Pre - Operation Inspection: Before each use, a thorough inspection of the crusher should be carried out. This includes checking the mechanical components such as the jaws, hammers, or cones for wear and damage. The drive system, including belts and gears, should also be inspected to ensure proper functioning. Any issues found should be addressed before starting the crusher.
• Material Feed and Size: The material to be crushed should be fed into the crusher at a consistent rate and size. Over - feeding can lead to clogging and inefficient crushing. The feed size should be within the recommended range for the crusher type. Large lumps or foreign objects that can damage the crusher should be removed before feeding.
• Crushing Settings and Adjustment: The crushing settings, such as the gap between the crushing elements or the speed of the rotor, should be set according to the desired product size and the nature of the material. Incorrect settings can lead to over - crushing or under - crushing and can affect the efficiency and quality of the final product.
• Maintenance and Cleaning: Regular maintenance is essential to keep the crusher in good working condition. This includes cleaning the crusher to remove accumulated material, inspecting and replacing worn - out parts, and lubricating the moving components. The wear - resistant liners and other components should be checked regularly and replaced when necessary to maintain the crusher's performance.

Things to consider when purchasing Crusher

• Crushing Requirements: Consider the specific crushing tasks you need to perform. Determine the type of materials you will be crushing, the desired product size, and the production capacity. This will help you select the appropriate type and size of crusher and the suitable crushing settings.[!--empirenews.page--]
• Budget: Establish a budget for the crusher purchase. The cost can vary significantly depending on the type, size, and features of the crusher. Consider not only the initial purchase price but also the long - term costs such as maintenance, energy consumption, and the cost of replacement parts. Look for a crusher that offers good value for money within your budget.
• Brand and Reputation: Select a reputable brand with a good track record in the industry. A well - known brand is more likely to provide reliable and durable equipment. Read customer reviews and ask for recommendations from other users or industry professionals to assess the quality and performance of different crushers.
• Technical Support and Spare Parts Availability: Ensure that the manufacturer provides good technical support and has a reliable supply of spare parts. Quick access to technical assistance and spare parts can minimize downtime in case of equipment failures and is crucial for the smooth operation of your crushing process.
• Features and Safety: Look at the features and safety mechanisms of the crusher. Consider whether it has the necessary adjustment capabilities, safety guards, and vibration - damping features. Also, think about the ease of operation, maintenance requirements, and any additional features such as automation and energy - saving options that may be beneficial for your specific application.

Terms of Crusher

• Crushing Capacity (Throughput): The amount of material that the crusher can process in a given time period, usually measured in tons per hour. It is an important factor in determining the productivity of the crusher and should match your production requirements.
• Reduction Ratio: The ratio of the size of the feed material to the size of the crushed product. It indicates the extent to which the crusher can reduce the size of the material and is a key specification for evaluating the performance of the crusher.
• Crushing Chamber Size: The dimensions of the area where the material is crushed. The size of the crushing chamber affects the maximum feed size and the capacity of the crusher. Larger crushing chambers can generally handle larger feed materials and have a higher capacity.
• Power Consumption: The amount of energy the crusher consumes during operation, usually measured in kilowatts - hour (kWh). Understanding the power consumption helps in estimating the operating costs and choosing an energy - efficient crusher.
• Warranty and Service Agreement: The warranty offered by the manufacturer and the terms of the service agreement, including what is covered, for how long, and the availability of technical support and spare parts. A comprehensive warranty and service agreement can protect your investment and provide peace of mind during the operation of the crusher.