STCrushers Is A Professional Minging Equipment Manufacturer since 2004, Providing High Quality Crushers, Sand Making Machines, Drying Equipment and more.
STCrushers Is A Professional Minging Equipment Manufacturer since 2004, Providing High Quality Crushers, Sand Making Machines, Drying Equipment and more.
When the Wilson Quarry—a 20-acre family operation in Ohio—faced a 40% profit drop in 2022, they rejected flashy "smart crushers" and bet on low-cost, high-impact retrofits. The result? A 19% boost in productivity and $78,000 saved annually. Here’s their blueprint.
The Problem: Outdated Workflow, Not Equipment
Background: Producing 50,000 tons/year of limestone aggregates for local road projects.
Pain Points:
Manual adjustments: Workers spent 3 hours/day tweaking jaw crusher settings.
Energy waste: 28% of power consumed during idle conveyor runs.
Fines overproduction: 18% of output was undersized (<4.75mm), sold at 60% discount.
The Fix: Four Affordable Upgrades ($55,000 Total)
1、Automated Gap Adjustment Kit ($12,500)
Retrofit hydraulic rams on their 2008-model jaw crusher, enabling remote CSS changes in <2 minutes.
Result: Reduced adjustment downtime from 3 hours to 22 minutes daily.
2、Variable Frequency Drives (VFDs) on Conveyors ($18,000)
Installed ABB VFDs to slow belts during low-feed periods, cutting motor energy use by 37%.
3、Pre-Screen Mesh Installation ($9,500)
Added a 10mm mesh grizzly screen before the crusher to remove undersized material.
Result: Fines production dropped to 9%, increasing premium product revenue by $32,000/year.
4、Used Wear Part Resurfacing ($14,000)
Partnered with a local metal workshop to weld hardfacing on old jaw plates, extending lifespan by 160%.
Owner Quote:
"We almost leased a $300K ‘smart’ crusher, but these tweaks delivered 80% of the benefits for 18% of the cost." – Mark Wilson, Owner
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