machine produces crushed granite

1. PAIN-POINT DRIVEN OPENING

Are escalating operational costs and inconsistent output eroding your aggregate production margins? For plant managers and contractors, the process of producing specification-grade crushed granite is fraught with persistent challenges. Inconsistent feed size from the primary crusher leads to frequent choke-ups and excessive wear in secondary crushing stages, directly increasing your liner replacement costs and unplanned downtime. The need for multiple processing stages to achieve the required cubicity and fines ratio for asphalt or concrete adds complexity, energy consumption, and footprint to your operation. Furthermore, the high abrasiveness of granite accelerates component wear in standard machinery, resulting in unpredictable maintenance cycles that disrupt your entire production schedule.

How do you increase throughput of high-quality, saleable product without expanding your plant’s footprint? Can you reduce your cost-per-ton for wear parts while maintaining consistent particle shape? Is there a solution that simplifies your flow sheet while delivering the precise product gradations your projects demand? The efficiency of the machine that produces crushed granite is the central determinant of your profitability.

2. PRODUCT OVERVIEW

This content addresses the Nordberg® HP Series Multi-Cylinder Hydraulic Cone Crusher, a tertiary/secondary crushing solution engineered specifically for high-volume production of premium crushed granite aggregates.

Operational Workflow:

1. Feed Introduction: Sized feed material (typically -250mm) from a primary jaw crusher is directed into the crusher’s feed hopper.
2. Inter-Particle Comminution: Material enters the crushing chamber where the rotating mantle compresses it against the concave liners. The multi-cylinder hydraulic system provides a consistent, high-pressure crushing force.
3. Dynamic Setting Adjustment: The crusher’s setting can be adjusted hydraulically during operation via an automation system to compensate for wear or change product specification without stopping production.
4. Product Discharge: Crushed granite exits through the bottom of the chamber, with product size determined by the closed-side setting (CSS) and chamber profile.

Application Scope: Ideal for producing railway ballast, road base, concrete aggregate, and asphalt chips where strict particle shape (cubicity) and gradation control are critical. Suitable for stationary plants and large-scale contracting sites.

Limitations: Not designed as a primary crusher for run-of-quarry boulders. Optimal performance requires pre-screened feed to remove fines. Maximum feed size is constrained by model selection.

3. CORE FEATURES

• Patented Multi-Action Crushing Technology | Technical Basis: Inter-particle compression & layered crushing action | Operational Benefit: Produces more crushed granite within specification on the first pass, reducing recirculation load and power consumption per ton | ROI Impact: Field data shows up to 15% higher yield of saleable product and a 10% reduction in specific energy consumption (kWh/ton).

• Hydraulic Dual-Acting Tramp Release & Clearing | Technical Basis: Dual-acting cylinders provide both downward force for crushing and upward stroke for clearing | Operational Benefit: Protects internal components from uncrushable material damage; clears a stalled cavity in under 60 seconds without manual intervention | ROI Impact: Minimizes risk of catastrophic failure; reduces downtime events by an average of 8-12 hours annually compared to mechanical spring systems.

• Wear Component Longevity Design | Technical Basis: Optimized chamber profiles & premium manganese steel alloys with even wear distribution | Operational Benefit: Liner life is extended due to reduced abrasive sliding motion in the crushing zone | ROI Impact: Reduces cost-per-ton for wear parts by up to 20% and extends scheduled maintenance intervals.

• IC™ Process Automation System Integration | Technical Basis: Real-time monitoring of crusher load, power draw, pressure, and temperature | Operational Benefit: Your operators can maintain optimal crusher performance; system automatically regulates feed rate to prevent overloads | ROI Impact: Maintains consistent product quality; prevents costly overload events; can increase total throughput by 5-10% through optimized continuous operation.

• Modular Wear Part Design | Technical Basis: Segmented liner sections & standardized fastening systems | Operational Benefit: Reduces liner change-out time by up to 50%; safer for maintenance personnel with less manual handling | ROI Impact: Lowers labor costs per maintenance event and increases plant availability.

4. COMPETITIVE ADVANTAGES

Performance Metric	Industry Standard (Spring Cone Crusher)	HP Series Cone Crusher Solution	Advantage (% improvement)
Product Yield (% in spec)	65-75%	80-90%	+15% (average)
Liner Change-Out Time	8-12 hours	4-6 hours	-50%
Specific Energy Consumption	Baseline (1.0)	0.85 - 0.90	-10% to -15%
Uptime Availability	~85% (planned & unplanned)	~92%+	+7 percentage points
Particle Shape Index (Cubicity)	Variable, higher flakiness ratio	Consistent, optimal cubicity	Industry testing demonstrates a 25% improvement in average cubicity index

5. TECHNICAL SPECIFICATIONS

• Capacity Range: Model-dependent, from 150 to over 1,200 metric tons per hour of crushed granite.
• Power Requirements: Electric motor drives ranging from 150 kW to 600 kW.
• Material Specifications: Engineered for highly abrasive materials like granite, basalt, quartzite. Maximum recommended feed size up to 300mm depending on model.
• Physical Dimensions: Varies significantly by model; designed with serviceability access in mind. A mid-range model (HP400) typically requires a footprint of approximately 6m x 3m at base level.
• Environmental Operating Range: Designed for stationary plant installation; operating ambient temperature range from -20°C to +40°C with appropriate lubrication systems.

6. APPLICATION SCENARIOS

#### Large-Scale Aggregate Producer & Asphalt Plant Supplier

• Challenge: Needed consistent supply of high-cubicity #57 stone (-25mm) for hot-mix asphalt producers but struggled with flaky particles from existing cone crushers, leading to mix compaction issues and customer complaints.
• Solution: Replaced two older spring cone crushers with a single HP500 cone crusher configured with a fine-liner chamber profile.
• Results: Achieved a particle shape index meeting state DOT premium aggregate specifications consistently. Recirculating load dropped by over 30%, increasing net usable output by an estimated 120 tons per shift.

#### Civil Engineering Contractor – Major Highway Project

• Challenge: Required on-site production of multiple graded products (base course, drainage layers) from blasted granite within tight project timelines; mobility setup time was critical.
• Solution**: Implemented a track-mounted HP300 cone crusher plant as their secondary/tertiary stage.
• Results**: The plant was relocated between three different stockpiling areas within the site with less than one day of setup time each move. The automated setting adjustment allowed quick switches between product grades, enabling them to meet varying daily material demands and finish the earthworks phase two weeks ahead of schedule.

7 COMMERCIAL CONSIDERATIONS

Equipment investment is structured across several tiers based on required capacity (HP200 through HP900 models). Capital cost correlates directly with throughput capability and installed power.

Optional features that enhance the core machine produces crushed granite include:

• Advanced automation packages with remote monitoring telematics.
• Dust suppression system integration kits.
• Special alloy liner options for extreme abrasion applications.
• Different chamber profiles (standard coarse/fine/extra-fine).

Service packages are available from basic commissioning support up to comprehensive annual maintenance agreements including planned inspections, liner change-outs, and predictive analytics review.

Financing options include traditional capital equipment loans operating leases tailored to project duration

8 FAQ

Q1 Is this machine compatible with our existing primary jaw crusher screening circuit?
A1 Yes provided proper engineering review is conducted The HP Series cone crusher is designed as a drop-in replacement or upgrade in most aggregate circuits Feed conveyor dimensions discharge heights

Q2 What is typical operational impact on our downstream vibrating screens?
A2 By producing more consistently shaped product with fewer elongated particles screen blinding is often reduced This can lead improved screening efficiency longer panel life

Q3 Are commercial terms negotiable based on fleet purchase or long-term service commitment?
A3 Volume pricing structures are available for multiple-unit purchases Significant value can be realized through bundled service agreements which offer fixed-cost maintenance planning

Q4 How long does implementation take from order commissioning?
A4 Lead times vary by model complexity For standard models delivery typically ranges months Site preparation foundation pouring must be completed prior arrival Commissioning supervised start-up requires approximately one week

Q5 What operator training provided?
A5 Comprehensive training included covering safe normal operation routine maintenance checks basic troubleshooting procedures conducted both classroom on-site during commissioning

Q6 Can this machine produce manufactured sand fines from granite?
A6 While capable producing some fines it optimized producing coarse aggregates For dedicated sand production specific Vertical Shaft Impactor VSI configuration recommended achieve correct grading shape