Common Mistakes in Crusher Plant Operation and How to Avoid Them

Operating a crusher plant efficiently requires not just the right equipment but also careful attention to best practices. Even experienced operators can make simple mistakes that reduce output, increase wear, and cause downtime. Understanding these common pitfalls can save both time and money while extending the life of your machinery.

1. Ignoring Proper Feeding Techniques
One of the most frequent mistakes in crusher operations is feeding material unevenly or in sizes larger than the crusher can handle. This can lead to blockages, increased wear on liners and blow bars, and inconsistent output. To avoid this, maintain a consistent feed size and rate using feeders or grizzlies for pre-screening, and monitor feed patterns regularly to ensure smooth operations.

2. Overloading the Crusher
Operating a crusher beyond its design capacity may seem like a way to increase production, but it often causes motor overload, higher energy consumption, and frequent breakdowns. Avoid overloading by knowing the capacity of your equipment, preventing sudden feed surges, and using automation or alarms to monitor load levels.

3. Neglecting Regular Maintenance
Skipping routine maintenance is a common but costly mistake. Lack of lubrication, missed inspections, or delayed component replacement can lead to premature wear, unexpected downtime, and safety hazards. Following the manufacturer’s maintenance schedule, inspecting wear parts regularly, and keeping a maintenance log are essential for reliable performance.

4. Improper Adjustment of Crusher Settings
Incorrectly setting the crusher’s Closed Side Setting (CSS) or rotor speed affects product shape, efficiency, and component life. Use adjustable features such as floating shafts in cone crushers, set the equipment according to material type and desired output, and train operators on proper adjustment procedures to avoid inefficiencies.

5. Poor Screening and Washing Practices
Failing to screen and wash material adequately can result in contamination, inconsistent product quality, and the need for reprocessing. Ensure proper screen selection and deck configuration, utilize advanced washing systems like Taurian TWS series, and monitor moisture content to maintain clean and high-quality output.

6. Not Monitoring Key Operational Parameters
Many plant issues arise from ignoring critical parameters like vibration, temperature, or throughput. Early warning signs often go unnoticed until they cause component failure. Using sensors, automation systems (like Taurian T-Link or Terratrak monitoring), and regularly checking operational metrics helps operators react promptly and prevent damage.

7. Lack of Operator Training
Even the most advanced plant is only as effective as its operators. Insufficient training leads to inconsistent production, higher accident risk, and inefficient use of equipment. Regular training sessions, sharing best practices, and encouraging operator feedback can greatly enhance plant performance and safety.