The Costly Reality of Crusher Blockages

In the aggregates, mining, and recycling industries, crushing equipment is the heart of the operation. But nothing brings a plant to a standstill faster—and more expensively—than a crusher blockage. This common yet critical issue leads to unexpected downtime, increased maintenance costs, and significant production loss. The good news? With expert knowledge and proactive strategies, most blockages are entirely preventable.

Why Do Crushers Get Blocked? Understanding the Root Causes

A blockage, often referred to as "bridging" or "packing," typically occurs when material, particularly wet, sticky, or oversized feed, accumulates faster than the crusher can process it. The main culprits are:

1. Improper Feed Size: Feeding material that exceeds the crusher's recommended maximum size can cause wedging.

2. Excessive Moisture and Clay: Wet material, especially with high clay content, can cling to the crusher walls, compact, and choke the cavity.

3. Overfeeding: Trying to push too much tonnage through the machine too quickly overwhelms the chamber and leads to congestion.

4. Liner Wear: Worn-out mantles or liners can change the crushing cavity profile, increasing the likelihood of material sticking and bridging.

5 Expert Strategies for Prevention and Maximum Uptime

Eliminating blockages is key to maintaining high productivity. Implement these professional tactics:

1. Optimize Your Feed Material

Use a grizzly screen or scalper ahead of the primary crusher to remove fines and highly oversized material. This drastically reduces the amount of sticky or excessively large rock entering the main chamber, allowing the crusher to focus on its core task.

2. Control the Feed Rate (The Golden Rule)

Never "choke feed" your crusher unless specifically recommended for your machine type and material. Monitor amp draw and hydraulic pressure continuously. Use an automated feed control system to regulate material flow, keeping it consistent and within the manufacturer's specified limits.

3. Manage Moisture and Stickiness

If processing wet or clay-heavy material, consider using pre-screening and pre-washing techniques. For immediate relief, ensure your operation allows sticky material to partially air-dry before crushing. Some operations successfully use small additives to break the surface tension of the clay.

4. Regular Liner and Wear Part Inspection

A small change in a liner's profile can have a huge impact on flow. Implement a rigorous inspection schedule. Replace worn wear parts promptly to maintain the optimal crushing cavity design and minimize areas where material can collect and compact.

5. Proper Clearing Procedure (Safety First)

If a blockage occurs, never attempt to clear it manually without following strict Lock-Out/Tag-Out (LOTO) and site safety protocols. Utilize non-contact methods like specialized hydraulic rock breakers or, if applicable, the crusher's automated tramp release system to clear the chamber safely and efficiently.

Stop viewing blockages as an inevitable part of crushing. By applying these five expert strategies, you can minimize downtime, protect your equipment, and crush your production goals.