Improve Production Efficiency with Our Rock Crushing Equipment

Crushing involves just what it sounds like—reducing large rocks and mineral deposits to make them into smaller, marketable aggregate products like gravel. Easy, right? Not quite. The type of rock crushers you need—cone, impact, jaw, gyratory, and more—largely depends on your site, the product you want to make, and how much you need to produce. Kemper Equipment can help you determine the best crushing equipment to meet your project goals every time.

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If you are a rock, sand, gravel, or mineral processing industry veteran, you know that several different types and styles of crushing equipment are used at crushing and screening plants.

An individual crusher's construction and capabilities also dictate where in your aggregate processing operations it will fit. That is, you may have multiple types of crushers situated in primary, secondary, tertiary (third), and quaternary (fourth) stations in a circuit format to perform the necessary material reduction. Each type of crusher brings unique strengths and benefits to the process.

Kemper Equipment specializes in designing the best crusher systems using top-quality brands and equipment to help you extract material, break it down into usable products, and get it to market economically and efficiently.

We've been helping mining operations, asphalt companies, and other industrial material handlers improve efficiency, save money, and move products faster since 1981.

Rock Crusher Types

Here at Kemper Equipment, we source our rock crushers from only the best crusher brands in the business. We also custom-design top-performing crusher systems from the industry's best equipment that will work hard to make finished aggregate products like crushed stone, geosynthetic aggregates, sand and gravel, fertilizer, lime, specialty mineral products, recycled asphalt, salt, coal, and slag. We design unique systems, so all your crushing needs are met, whether at a fixed job site or in situations that require mobile crushing capabilities.

Depending on their best fit, these types are just some of the rock crushers we typically install in primary, secondary, tertiary, quaternary, or final-reduction crushing stations.

Jaw Crushers

Jaw crushers are also known as "rock breakers" and are used to break up larger, harder materials into more manageable pieces. They tend to do well with many different types of materials and don't display as much wear and tear as impact-style rock crushers. They also produce minimal fine materials and dust, but the finished product almost always requires secondary crushing.

Gyratory Crushers

Gyratory crushers feature a conical head and concave surface (often lined with manganese steel) and break apart material by compression through what is known as eccentric movement. Similar to jaw crushers, gyratory crushers are often utilized in primary aggregate crushing stations, though they may sometimes be used in secondary applications, as well.

Impact Crushers: VSIs and HSIs

Impact-style crushers include vertical shaft impactors (VSIs) and horizontal shaft impactors (HSIs). They are best used with less abrasive rock types, like limestone. These machines break apart material by the impacting forces of certain wear parts, like blow bars and impact plates. Some operations use impact crushers to achieve a cubical product after using another type of rock crusher.

Cone Crushers

Like jaw and gyratory crushers, cone crushers work by compression, meaning they reduce materials by squeezing them until they break apart. Cone crushers are built with a rotating mantle in a concave bowl lined with manganese, but the crushing chamber in cone crushers is not as steeply angled. They can accept medium-hard to very hard and abrasive feeds that might be dry or wet, though not sticky.

Portable Rock Crusher Plants

Depending on the length of your project and how mobile your rock crushing equipment needs to be, you can choose either stationary or portable/modular crushing plants. These self-contained rock crushing and material handling plants are better suited to smaller projects and can be moved from project to project as necessary for more mobile crushing capabilities on the job site.

Contact Us to Discuss Your Crushing Equipment Needs

Choosing the right rock crushers is a crucial part of maximizing the production and profitability of your crushing and screening business. If you need an update to your equipment or have a job site that requires new heavy-duty crushers, our rock crushing equipment experts can help. Our experience with crushing and screening plants of all sorts means we will help you design and build rock crushing equipment that works for your material handling needs.

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Need Replacement Parts or Service for Your Existing Crushing Equipment?

Need parts for your jaw crushers, impact crushers, gyratory crushers or cone crushers? We've got them! We stock components and wear parts for a wide variety of crushers and offer top-notch service from our in-house service techs. Learn more at QuarryParts.com or contact us for details!

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Everything You Need to Know About Rock Crushers

Do you need to process sand, gravel, minerals, rock, or other aggregate products and have not yet purchased or leased crushing equipment?

Finding the right rock crusher or crushers for your unique operations may seem straightforward, but putting together an efficient crushing circuit is actually a delicately balanced feat of engineering.

Stages of Rock Crushing: Crushing Stations

It is common to use multiple crusher types within a project and set them up as stations in a circuit format to perform the necessary material reduction work. In many cases, primary, secondary, and tertiary, and quaternary stations are installed to reduce the rock to the desired size, shape, and consistency.

Of course, not all projects require all the stations or stages. Sometimes, primary crushing alone may offer enough reduction for your needs.

For instance, if the final size of your product only needs to be between 4 inches and 6 inches, a primary jaw or impact crusher can accomplish your goals. However, you will likely require a much finer product, and that means incorporating up to three—or even four—stations with a variety of crusher types.

1. Primary Crushing

As the first stage in a crushing circuit following extraction from a mine site, (or in the case of recycled asphalt production, delivery to the RAP processing plant via truck transport), primary crushing reduces material to a size and shape that can be handled by the secondary crusher.

Typically, the minimum setting on most primary crushers will be about 4 to 6 inches, as noted above. Compression-style jaw, cone, impact crushers, and gyratory crushers are most often appropriate as primary crushing equipment types, though there can be overlap between primary and secondary crushers as far as suitable types.

2. Secondary Crushing

In secondary crushing, reduction ratios become an essential consideration. Knowing just how fine you need your final output to be, along with the feed requirements of your tertiary or final reduction crushing station, will help you determine how much reduction needs to take place within this stage.

Cone crushers are often placed within the secondary crushing station because they are versatile in terms of feed, closed side setting, speed, and throw. With cone crushers, though, it is essential to operate them at consistent choked settings to keep productivity up.

3. Tertiary/Quaternary/Final Reduction Crushing

The goal of the tertiary (third), quaternary (fourth) or final reduction stage of the crushing process is to size and shape rock or other material into a marketable product. Again, there may be overlap between stages in terms of which crusher styles work best.

Cone crushers, vertical shaft impactors (VSIs), horizontal impact crushers, or even high-pressure grinding roll crushers may be used in the final reduction position.

Types of Rock Determine the Crushers You Need

Sandstone, limestone, gravel, and granite are arguably the most common aggregates used in the construction industry today, but these rocks have very different hardness and abrasiveness characteristics.

The type of rock you plan to focus on processing in your operation will dictate the types of rock crushers you'll need to include in your crushing circuit.

The more you know about the type of rock you wish to crush and what its end-use will be, the easier it is to choose the best equipment to achieve your project goals.

Continue reading our blog article, "Everything You Need to Know About Crushers" to learn even more.

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Trust Kemper to deliver aggregate solutions. Whether you're building a new aggregate production plant, revamping an existing system, need engineering help on a mining equipment design project, or upgrading your aggregate equipment. Our knowledgeable and experienced design and build team of engineers will put together the right system for your unique operation that maximizes your aggregate production and reduces your costs.

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