Crushing plants - What are they and how do I set one up?
If you're working in construction, demolition, or recycling, a crushing plant can help you turn raw materials like concrete, asphalt, and rock into usable products. Whether you're looking to produce base material for roads or aggregate for resale, setting up a crushing plant can increase your efficiency and profitability.
What is a crushing plant?
Are you a construction business owner or contractor looking to crush concrete, rock or asphalt? If so, you may be wondering what a crushing plant is. A crushing plant is a row of machines that break down large chunks of material into smaller pieces in the quickest most efficient way.
Crushing plants are an important part of the mining, quarrying, and recycling industries. They can even be set up as stationary plants or mobile ones, depending on your business's needs. In this blog post, we will find out the different kinds of crusher plants in more detail.
Crushing plant setup
A crushing plant setup is a series of machines that are designed to take large pieces of concrete, asphalt or rock and break them into smaller pieces. The crushed material can then be used for construction, landscaping, and other purposes.
Stage 1 of the crushing plant - Excavator
There are many different kinds of machines used in a crushing plant. At the beginning of the plant is the excavator. This scoops up large blocks of concrete, rock or asphalt from your stockpile and places them into the first crusher. There are typically two types of crusher machines used in a plant setup: a jaw crusher or an impact crusher. There are lots of different sized and shaped excavators and buckets available, so you will always be able to find one for your specific job. You can check out all the different types of excavators here. You might also want to consider a grated for your projects if you are looking to create roads and paths with your crushed aggregate. What is a grader? | Machinery Partner
Stage 2 of the crushing plant - Crusher
A jaw crusher is great for breaking down very large pieces of rock into smaller more manageable sizes. These smaller chunks can then be fed into an impact crusher. These work by metal rotors smashing the material against the inside an impact chamber. Creating a much smaller material that is a similar shape and size. If you are thinking of running a jaw and impact crusher in the sequence you should read this blog on primary crushers this has all the information you need to know. And, if you want to know more about the differences between jaw and impact crushers, just click the link!
You can also run a crushing plant without an impact crusher, especially if your budget is tighter.
Stage 3 of the crushing plant - Screener
If you're setting up a crushing plant, a screener can be an essential piece of equipment. It can help you to get the most out of your crushers by sorting the materials they make into stockpiles of the same size. You can then use these directly on your projects for landscaping or to make pavement fill or sell them for a profit!
When choosing a screener for your crushing plant, it's important to select one that is durable and easy to maintain. You'll also want to think about the type of material you'll be working with and the product you want to make. With so many options on the market, it's important to work with a reputable supplier who can help you choose the right screener for your needs. Machinery Partner is always here to help you choose the best screener for your business with a full range of scalping screens and trommels .
Setting Up a Crushing Plant
When setting up a crushing plant, consider the following steps:
- Site Selection: Choose a location with adequate space and accessibility.
- Equipment Selection: Select machines that match your material type and desired output.
- Layout Planning: Arrange equipment to optimize workflow and minimize material handling.
- Power Supply: Ensure a reliable power source for all equipment.
- Permits and Regulations: Obtain necessary permits and comply with local regulations.
Proper planning and setup are crucial for the plant's efficiency and compliance with safety standards.
Should I use a mobile or stationary crushing plant setup?
When deciding between mobile and stationary crushing plants, you should think about the pros and cons of each setup.
Mobile Crushing Plants:
- Advantages:
- Easily transported between sites.
- Quick setup and teardown.
- Ideal for short-term projects.
- Considerations:
- May have lower capacity compared to stationary plants.
- Potentially higher operating costs.
Stationary Crushing Plants:
- Advantages:
- Higher production capacity.
- Lower operating costs over time.
- Suitable for long-term projects.
- Considerations:
- Requires more time and resources to set up.
- Less flexibility in relocation.
Choose the type that best fits your project's duration, location, and production needs.
Mobile crushing plants are easily transportable, cost-effective, and can be moved around quickly to different work sites. Mobile crushing plants require regular maintenance and may use more fuel, plus they can’t process as many materials at once. On the other hand, stationary crushers are usually located in one spot, so there’s no need to move them from job site to job site. This does however mean that you will lose the flexibility of being able to move it when needed and you will need to have a permanent location where the crusher and or screener will stay.
The choice between a mobile or stationary crushing plant depends on your needs: mobile units are better for short-term projects that require frequent travel while stationary ones are recommended for more time-intensive jobs that remain in one spot.
What are the Benefits of Using a Crushing Plant
- Cost Savings: Reduce expenses by processing materials on-site.
- Efficiency: Streamline operations and reduce material handling.
- Versatility: Produce various sizes and types of aggregate.
- Environmental Impact: Lower carbon footprint by minimizing transportation.
I just have a crusher at the moment - why should I upgrade and setup a full crushing plant for my business?
When it comes to crushers, bigger is better. Having just a crusher for your business can be fine for gravel, cement, and concrete but when it comes to more complex crushing materials, such as minerals, ore and metals, the jaw crusher isn't always enough.
Setting up a crushing plant gives you the ability to process higher volumes of material in different sizes much faster than a jaw crusher alone would. If you're processing different kinds of materials or just need to process large amounts of material quickly, then setting up a crushing plant is essential.
A crushing plant gives you access to larger crushers and screens so that you can process more material in fewer passes. You'll also be able to keep production running longer with smaller machines because there's less wear on them when compared with just using one crusher over extended periods.
In short, if you need high-volume crushing capabilities and are looking to expand your business into more complex areas of crushing materials, then setting up a crusher plant is your best choice! All in all, setting up a full crushing plant offers greater flexibility, better efficiency and improved productivity rather than relying on a single crusher alone.
Can I match any crusher with any screener?
Setting up a crushing plant involves careful consideration and selection of all its machines to make sure they match each. This is the only way you can make quality materials with minimal wear and tear on machinery.
You should always think about the tones per hour (tph) each machine can handle. If your jaw crusher works at 200 tph, you can’t match it with an screener than can only handle 50 tph!
When you are setting up a crushing plant you also need to think about the feed heights of the machine's hoppers compared to the conveyor height of the machine in front of it. Take a look at this setup below. This is a jaw crusher feeding a screener. See how the conveyor of the jaw crusher nicely feeds into the screener?
Getting a bit complicated? Don’t worry - Machinery Partner are here to help. We have decades of experience when it comes to crushing and screening and can help you with all kinds of crushing plant setups and advice. Get in touch with a Machinery Partner expert today!
Machinery Partner will find you the best crushing plant setup
Need crushers, screeners or excavators for your crushing plant setup?
Machinery Partner has you covered! We have a large selection of crushers, screeners and excavators for sale at competitive prices. Our team of experts can help you navigate the range to find the best machinery for your specific crushing plant and material need.
Whether you're crushing stone, asphalt, or metal waste and debris, Machinery Partner can help you put together a set of crushers, screeners and excavators that will get the job done right. So if you want to get your crusher plant up and running quickly and efficiently, Machinery Partner is here to help. Call a Machinery Partner expert today!
FAQs: Setting Up a Crushing Plant
What is the difference between a crushing plant and a standalone crusher?
A standalone crusher is a single machine, usually used for one part of the crushing process. A crushing plant is a complete system that includes multiple machines, such as jaw crushers, impact crushers, screeners, and conveyors, all working together to process material from start to finish.
How much space do I need for a crushing plant?
It depends on your setup and production goals. A small portable plant might fit in a half-acre yard, while a larger stationary plant may require several acres. You’ll need space for stockpiles, material flow, and safe equipment access.
Do I need permits to run a crushing plant?
Yes. In most areas, you’ll need zoning approval, dust control permits, and possibly noise or environmental permits. Always check with your local authority before setting up your plant.
How much does it cost to set up a crushing plant?
Startup costs vary depending on equipment size and configuration. Small portable plants may start around $100,000 to $250,000, while larger setups can exceed $500,000. Financing options are available for most budgets.
Can I move a crushing plant between job sites?
Yes, if you’re using a portable or mobile plant. Tracked crushers and modular screeners are designed for easy transport and quick setup, making them ideal for contractors who work multiple projects.
What types of material can a crushing plant process?
Crushing plants can process concrete, asphalt, natural stone (like granite and limestone), and even mixed demolition debris. The key is matching your machine setup to the hardness and abrasiveness of your material.
