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Mining Industry: What a good way to choose a jaw crusher?

Sep 24, 2025

Mining Industry: What a good way to choose a jaw crusher?

In fields such as mining, construction aggregate production, and road construction, jaw crushers have always occupied a “core equipment” position. They undertake the critical task of primary crushing of raw materials, and their performance directly affects the efficiency, cost control, and final profits of the entire production line. However, faced with a wide range of models, huge price gaps, and uneven quality of manufacturers in the market, many purchasers easily fall into the dilemma of “feeling dizzy when looking at parameters, hesitating when comparing prices, and regretting after purchasing”.

In fact, the core of choosing a jaw crusher is not to “buy the most expensive one”, but to “select the most suitable one”. Only by comprehensively judging based on your own material characteristics, production needs, equipment performance, and after-sales support can you avoid problems such as “a small horse pulling a large cart” and “frequent breakdowns and shutdowns”. This article will break down the scientific selection method from 5 key dimensions.

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First, Clarify Your “Rigid Requirements”: What Does Your Crusher Plant Actually Need?

The first step in choosing a jaw crusher is not to rush to look at models or compare prices, but to first figure out “what non-negotiable requirements your production scenario has for the equipment”. This is the basis for avoiding blind purchases and the foundation for all subsequent choices.

First Understand the “Material to Be Crushed”: Hardness, Humidity, and Particle Size Are Key

The characteristics of different materials directly determine the “adaptation direction” of the jaw crusher. Choosing the wrong one will lead to rapid equipment wear at best, and inability to produce normally at worst.

raw material of the crushering plant - Mining Industry: What a good way to choose a jaw crusher?

Hardness: Determines the Equipment’s “Durability”

The hardness of the material is the core basis for selecting the jaw plate material and crushing force. For example, when crushing limestone (Mohs hardness 3-4, relatively soft), ordinary manganese steel jaw plates can meet the needs; but when crushing granite or basalt (Mohs hardness 6-7, relatively hard), it is necessary to select high-chromium alloy or composite wear-resistant jaw plates. At the same time, the equipment frame must have sufficient rigidity to avoid deformation under long-term high pressure.

Humidity: Be Alert to the “Risk of Blockage”

If the raw material has high moisture content (such as clay ore or ore after rain), it is easy to stick and block in the crushing chamber, leading to production line shutdown. In this case, priority should be given to jaw crushers with “anti-blocking design”, such as expanding the discharge port, adding a spray device in the chamber, or using “arc-shaped jaw plates” to reduce material retention.

Particle Size: Match the “Feed Opening Size”

The maximum particle size of the raw material directly determines the feed opening size of the jaw crusher. There is a general rule in the industry: the maximum particle size of the material is approximately 70%-80% of the feed opening size. For example, if the maximum particle size of your raw material is 500mm, the feed opening size must be at least 600mm or more. If the feed opening is too small, large materials cannot enter; if you force feed, it will cause equipment jamming and motor overload.

Then Determine the “Output Target”: Capacity, Particle Size, and Crushing Ratio Must Be Clear

Without clear production requirements, choosing equipment is like “touching an elephant blindfolded”. You must know “how much to produce per day”, “how large the crushed material should be”, and “how fine it needs to be crushed” to accurately match the equipment.

Capacity (TPH): Don’t Just Look at “Parameters”, Calculate “Actual Needs”

Capacity refers to the hourly processing capacity of the equipment (tons per hour, TPH), which needs to be deduced based on your daily and annual production targets. For example, if your project requires a daily output of 500 tons, calculated based on 8 working hours per day, the actual capacity of the equipment needs to reach 60-70 TPH (reserve 10%-20% redundancy to cope with raw material fluctuations).

More importantly, the capacity must match the entire crushing line. If the capacity of the jaw crusher is 100 TPH, but the subsequent secondary cone crusher can only handle 80 TPH, the capacity of the jaw crusher will be wasted, forming a bottleneck of “high front and low back”.

Discharge Particle Size: Connect to “Downstream Processes”

You need to clarify “what the crushed material will be used for”—whether it will be directly used as construction stones or need to enter secondary crushing. For example:

- If a standard cone crusher is used for secondary crushing later, the discharge particle size of the jaw crusher must be controlled within 4 inches (about 100mm) to ensure it can smoothly enter the feed opening of the cone crusher;

- If you need to finally produce fine materials of 1/4 inch (about 6mm), you need to match a “short-head cone crusher” for tertiary crushing after the jaw crusher and secondary cone crusher.

出料 - Mining Industry: What a good way to choose a jaw crusher?

Crushing Ratio: Strictly Abide by the “Upper Limit of 6:1”

The crushing ratio is the “ratio of the maximum particle size of the raw material to the maximum particle size of the discharge”. It is recommended that the crushing ratio of the jaw crusher does not exceed 6:1—this is the key to ensuring crushing efficiency and equipment life. For example:

- A jaw crusher with a feed size of 24 inches (about 600mm) should have a maximum discharge size of 4 inches (24÷6=4);

- If you want to crush from 4 inches to 1.5 inches, it should be handled by a secondary cone crusher (4÷2.6≈1.5, which meets the crushing ratio requirement) instead of forcing the jaw crusher to “crush beyond its range”.

Focus on “Core Parameters”: These 3 Indicators Determine Whether the Equipment Is Easy to Use

After clarifying the needs, it’s time to focus on the technical parameters of the equipment itself. Some parameters seem “insignificant”, but they directly affect production efficiency and operation and maintenance costs.

Feed Opening and Jaw Plates: Choose the Right Size to Reduce Wear

Feed Opening Size: Don’t “Pursue Larger” or “Make Do”

The feed opening size must strictly match the maximum particle size of the raw material (refer to the 70%-80% rule mentioned earlier), and it is not necessarily better to be larger. If the feed opening is far beyond the actual needs, it will cause “small materials to be idle in the chamber”, increasing energy consumption and jaw plate wear; if the feed opening is too small, large materials will jam, leading to frequent shutdowns for cleaning.

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Jaw Plate Material: Choose “Wear Resistance Level” According to the Material

Jaw plates are spare parts of jaw crushers, and their material directly determines the replacement frequency and cost:

- For ordinary materials (limestone, gangue): Choose Mn13 high manganese steel jaw plates for high cost-effectiveness;

- For medium-hard materials (iron ore, sandstone): Choose Mn13Cr2 composite jaw plates, whose wear resistance is increased by 30%;

- For high-hard materials (basalt, granite): Choose high-chromium alloy jaw plates, whose service life can be more than twice that of ordinary jaw plates.

Closed Side Setting (CSS): Adjustability Is Important

The closed side setting (CSS) refers to the “minimum gap when the jaw plates are closed”, which directly determines the fineness of the discharge particle size. Two points should be paid attention to when selecting:

Whether It Supports “Flexible Adjustment”: Priority should be given to hydraulic adjustment CSS instead of manual adjustment. Hydraulic adjustment can accurately control the discharge particle size through buttons, reducing the adjustment time from “several hours” to “several minutes” and greatly reducing downtime;

Whether the Adjustment Range Matches the Needs: For example, if you need to produce two specifications of stones (30mm and 50mm) at the same time, the CSS adjustment range of the equipment must cover 20-60mm to avoid “unqualified products due to improper adjustment”.

Lubrication and Cooling System: Related to Equipment “Reliability”

The moving parts of the jaw crusher, such as bearings and eccentric shafts, operate under high pressure and high speed for a long time. Insufficient lubrication will easily lead to overheating, wear, or even scrapping. Focus on the following when selecting:

Lubrication Method: Priority should be given to “pressurized filter lubrication”. This method can force the filtered clean lubricating oil into key parts, which improves the lubrication effect by 50% compared with ordinary “splash lubrication” and reduces bearing failures;

Whether It Has a Cooling Device: When used in high-temperature environments (such as summer in the south or underground operations), a jaw crusher with an “oil cooling or water cooling” lubrication system should be selected to avoid deterioration of the lubricating oil due to high temperature and ensure continuous operation of the equipment.

Evaluate “Equipment Performance”: Durability, Efficiency, and Safety Are All Indispensable

Meeting the parameters is only the “basis”, and the actual performance of the equipment is the “guarantee for long-term profits”. Many purchasers only look at the parameter table but ignore the “durability, efficiency, and safety” in actual use, which ultimately leads to a sharp increase in later operation and maintenance costs.

Durability: The Body and Frame Must Be “Durable”

In mining production, the jaw crusher endures thousands of impacts and extrusions every day. Insufficient body strength will lead to frame deformation and weld cracking. Pay attention to the following when selecting:

Body Material: The frame should be integrally welded with “Q355B high-strength steel plate” instead of ordinary steel plate splicing. The tensile strength of Q355B is 20% higher than that of ordinary steel plates, which can withstand greater impacts;

Structural Design: Focus on whether the “stress concentration parts” (such as the feed opening and eccentric shaft seat) have been “thickened and reinforced” or “arc transition” treated to reduce fatigue damage during long-term use.

Stone Crusher Plant 01 - Mining Industry: What a good way to choose a jaw crusher?

Efficiency: It Should Not Only “Work Well” but Also “Save Costs”

Equipment efficiency depends not only on “capacity” but also on “unit energy consumption”. For the same capacity of 100 TPH, equipment with low energy consumption can save tens of thousands of yuan in electricity bills every year.

Motor Power: Match the Needs Without Waste

The motor power is not necessarily larger. It needs to be matched according to the material hardness and capacity. For example, a 75kW motor is sufficient for crushing 100 TPH of limestone; while a 110kW motor is required for crushing 100 TPH of granite. Insufficient power will cause “motor stalling”, and excessive power will waste electricity.

Crushing Chamber Design: Improve “Material Gripping” Efficiency

Priority should be given to the “deep cavity V-shaped crushing chamber” instead of the ordinary shallow cavity. The deep cavity design can increase the “single feed amount” and allow the material to be “crushed one more time” in the chamber, which not only improves the capacity but also reduces material over-crushing and energy consumption.

Safety: Avoid “Production Accidents”

The mining operation environment is complex, and the safety design of the equipment is directly related to the life safety of the operators. Confirm whether the following functions are available when selecting:

Overload Protection: When the equipment is jammed or overloaded, it can automatically stop or reverse to avoid motor burnout and jaw plate breakage;

Safety Protection: Moving parts such as the feed opening and belt drive should be equipped with “removable guardrails” to prevent accidental contact by personnel;

Emergency Stop: The equipment body and console should be equipped with “red emergency stop buttons” to ensure that the equipment can be stopped immediately in case of emergencies.

Don’t Ignore “After-Sales Support”: This Is the “Long-Term Insurance” for the Equipment

Many purchasers only focus on the “equipment itself” when selecting, but ignore the “after-sales service”. As heavy equipment, the jaw crusher cannot do without the manufacturer’s support for later maintenance, parts replacement, and fault repair. A single “inadequate after-sales service” may cause the production line to shut down for several days, resulting in huge losses.

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The “Core Value” of After-Sales Service: Reduce Downtime

In mining production, “stopping for one day means losing one day’s profit”. The core role of after-sales service is to “solve problems quickly and resume production”. For example:

If the jaw plate is broken, can the manufacturer deliver the parts within 24 hours?

If the eccentric shaft fails due to equipment jamming, can the manufacturer send technicians to the site for maintenance within 48 hours?

These seemingly “small things” directly determine your production efficiency.

Three Key After-Sales Guarantees to Check

When selecting a manufacturer, clearly ask the following 3 points to avoid “verbal commitments”:

Parts Supply: Does the manufacturer have a “local parts warehouse”? What is the stock cycle of common parts (jaw plates, bearings, seals)? Does it provide “original parts” (non-original parts may not match the equipment, leading to reduced performance);

Maintenance Service: Does it provide “free on-site installation and commissioning”? What is the response time when the equipment fails? Is there a “regular inspection service” (proactively check for hidden dangers to reduce the probability of failures);

Warranty Policy: What is the warranty period of the whole machine? Are vulnerable parts (jaw plates, liners) covered by the warranty? Does the maintenance within the warranty period include “parts cost + labor cost”?

Choose the “Right Manufacturer”: Avoid “Shoddy Traps” and Find a Reliable Partner

The current crushing equipment market is “a mixed bag”—there are both old manufacturers with more than ten years of experience in the industry and small workshops with “OEM production”. Choosing the right manufacturer is equivalent to “choosing a long-term partner”, which can avoid many troubles in the later period.

How to Identify a “Reliable Manufacturer”? Three Judgment Standards

Look at Experience: Priority should be given to manufacturers with “more than 5 years of establishment”. Such manufacturers have mature production processes, stable supply chains, and have accumulated a large number of customer cases (you can ask the manufacturer to provide “on-site videos of customers in the same industry” to inspect the equipment operation on site);

Look at Strength: Does it have an “independent production workshop” (not a “trading company”)? Can it provide “customized services” (such as adjusting the crushing chamber design according to your raw material characteristics)? You can ask the manufacturer to “live broadcast the factory” to check the production equipment and testing process;

Look at Reputation: Judge through “customer reviews” and “industry reputation”. For example, search for the manufacturer’s name on industry forums and short video platforms to see the usage feedback of other customers; or consult local practitioners in the same industry to understand the manufacturer’s “after-sales reputation”.

Don’t Be Tempted by “Low Prices”: Calculate the “Total Cost”

The price gap of jaw crushers in the market is very large. Some manufacturers quote “20% lower than their peers”, but behind this may be “cost reduction by cutting corners”:

Using ordinary steel plates instead of high-strength steel plates, resulting in easy deformation of the body;

Using non-original motors with false power labels, which are easy to burn out;

“Shrinking” after-sales commitments and high maintenance fees in the later period.

Therefore, when selecting, you cannot only look at the “upfront cost (early purchase price)” but also calculate the “total cost”, including purchase price, energy consumption cost, parts replacement cost, and maintenance cost. A “cost-effective” equipment is often “slightly higher in early purchase price but lower in later operation and maintenance costs”, which is more cost-effective in the long run.

Conclusion:

Choosing a jaw crusher is essentially a “systematic decision based on your own needs”—from “clarifying raw material and capacity needs” to “focusing on core parameters”, and then to “evaluating equipment performance, after-sales support, and manufacturer strength”, every step must be taken carefully.

If you still have questions (such as “what size feed opening should I choose for crushing basalt?” or “what power motor do I need for a daily capacity of 800 tons?”), you can contact UNIQUEMAC‘s online customer service at any time. With 40 years of experience in R&D and production of mining equipment, we can provide one-stop services from “raw material analysis → equipment selection → scheme design → after-sales maintenance” according to your specific needs, helping you select a “suitable, durable, and efficient” jaw crusher to ensure the stable operation of the production line and continuous profit creation.