When your rock crusher starts showing signs of age, the instinct might be to start budgeting for a brand-new machine. But hold that thought. At Mellott, we know from decades of experience that a strategic rebuild can restore performance, extend equipment life, and save your operation serious downtime and capital expense while staying compliant with MSHA safety requirements.
So how do you know when it’s time to rebuild instead of replace?
Here are five signs it might be time to call in the experts—and why Mellott’s Rebuild Program could be the smarter move for your operation.
1. Your Crusher Still Has a Solid Frame
If the main frame or structure of your cone, jaw, or impact crusher is still in good condition, a rebuild is often the most efficient solution. Much of a crusher’s lifespan lies in its core components, and if those are still structurally sound, you’re sitting on an asset worth revitalizing.
✅ Good Candidate: No major cracks, warping, or corrosion
⚠️ Risk of Waiting: Frame damage is often irreversible. Rebuild before problems spread.
2. Maintenance Downtime Is Increasing
If your machine is breaking down more frequently or requiring more intensive maintenance, it may be time to overhaul the internal components. Worn bearings, bushings, or worn-out liners can cause performance to plummet, putting strain on the rest of your equipment.
✅ Good Candidate: Frequent repairs, but nothing catastrophic
💡 Pro Tip: A well-timed rebuild can often double the lifespan of certain internal parts.
3. OEM Lead Times Are Slowing Your Production
In today’s market, waiting 6–12 months for a new crusher can mean missed deadlines, delayed contracts, and frustrated customers. Rebuilding your existing
machine through Mellott’s rebuild program can get you back up and running much faster, and often with upgraded performance and reliability.
🚫 Avoid: Long shipping delays, tariff complications, and unpredictable costs
💥 In Stock: Mellott has rebuilt Metso HP and Symons classic cones available now—ready to ship.
4. You’re Looking to Upgrade Performance Without a New Purchase
Rebuilding doesn’t mean resetting your crusher to its original specs. It’s an opportunity to upgrade components, incorporate automation, and optimize wear parts for your exact application.
🔧 Options Include:
-
New liners for extended wear life
-
Modern hydraulic systems
-
Improved feed cone liners (ask us about rubber feed cone upgrades!)
5. Your Crusher No Longer Meets Production Targets
Throughput and efficiency tend to suffer when internal wear goes unchecked. If you’re struggling to hit your tonnage goals, but the crusher still has potential, a rebuild might restore the power you need—without the cost of starting over.
📈 Success Story: Customers often report 20–40% improvements in performance after a full rebuild.
Why Choose Mellott for your Rebuild?
Rebuilding a crusher isn’t just a mechanical process, it’s a strategic investment in your plant’s future. At Mellott, we offer:
-
In-stock rebuilt crushers ready to ship
-
Quick turnarounds with precision quality
-
Customized upgrades to improve performance
-
Lifetime support for your rebuilt unit
Don’t Wait for a Catastrophic Failure
A proactive rebuild can save you from a costly emergency—and give your crusher a second life. If your equipment is showing any of the signs above, it’s time to explore your options.
📞 Contact Mellott today to discuss whether your crusher is a candidate for a rebuild.
