When it comes to crusher feed, the more uniform its shape and percentages of size range, the more effective the crusher becomes.

Range of feed material goes from small to large. The more of the feed product that can be removed that is equal to or smaller than the discharge setting, the more effective the crusher becomes. The large feed size maximum is best determined by putting nothing larger than three quarters the size of the effective feed opening. (This is not the largest opening of the feed end.) If that kind of sizing control can be accomplished, then the crusher needs to be flooded with enough volume of that material to keep the crusher filled at all times.

Woefully, this condition is rarely obtained. That is why choice of jaw, gyratory, cone and roll wear parts become so job specific. It’s difficult to control feed blends, types and sizes, and this has lead to the creation of many options in wear parts and machine types and sizes.

The more reduction stations in a crushing operation, the more effective each crusher becomes. Large volume mines have learned by experience that it usually takes 5 crushing stages to optimize the use of each crusher. Having that many stages of crushing is not viable in most cases, however, so the next best thing is to apply the best product, and proper wear parts, for the sizing job at hand.