Every hour your crusher is down, money is lost.
There are more than 180 recoverable operating hours hiding in a typical cone crusher every year. These hidden hours of additional run time live in liner design, change-out procedure, part quality, and how fast someone picks up the phone. Here’s where those hours are, and how our engineers get them back.
Solutions
The downtime that never gets logged as downtime
You already know the cost of a stopped crusher, because you’re the one who has to explain it. What’s harder to see is the downtime that never gets logged as downtime, the extra four hours on a liner change, the liner set that came out early, the shift spent waiting on a part that should have been on the shelf. None of it is dramatic. All of it adds up.
Most operations focus on the big failures and accept the small losses as the cost of running rock through a crusher. In our experience, the small losses are where the recoverable hours actually live.
The math is simple. The opportunity is enormous.
Where the hours hide, from our field data
Lever
Hours / year
Liner optimization
+2% annual TPH
Belt change & tensioning improvement
36
Main frame liner change improvement
36
Wear part optimization (arm guards, feed plates, ore contact points)
36
Troubleshooting support response
24
Longer liner wear life (25% longer)
24
Bushing failure prevention
12
Fully stocked parts partner
12
Fully stocked parts partner
12
NET ANNUAL OPPORTUNITY (after overlapping levers are netted out)
180 hours
At a gold mine valuing production at $290,000/hour, the gross metal at risk is a $52M opportunity, from one crusher.*
* Actual savings vary by site and bottleneck.
180
Recoverable hours per
crusher per year*
$52M
Gross metal at risk at $292,000/hour assumption
35%
EBITDA margin assumption
$18.4M
EBITDA impact
How we recover them
1
We redesign the liner for your application. Not the catalog's.
Chamber profile, alloy, and geometry engineered for your feed, your ore, and your site conditions.
2
We shorten the change-out.
Our engineers have run these procedures. Small changes to sequence and tooling take hours off every shutdown.
3
We answer the phone.
24-hour technical support by phone and unlimited email support, at no charge. The fastest way to cut a failure short is to talk to someone who's seen it before.
4
We keep the parts on the shelf.
We carry the largest mining-duty Raptor® aftermarket inventory in the world, Nordberg MP® Series aftermarket inventory is expanding, and we respond to quotes within 24 hours.
A gold mine extended secondary liner life by +138% with an Optimum Crush engineered liner set, cutting change-outs and recovering production hours.
Who you'll work with
Keep digging
Crusher down right now?
Call +1 (414) 909-8800. Someone who knows your machine will pick up: day, night, or weekend. No charge, no ticket queue. And when you’re ready, get us to your site; that’s where the hours come back.
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