The crushing process plays a critical roll in transforming raw rock into useable sizes to producing aggregate material for construction, building roads or in mining operations. At Mellott, we help customers optimize every stage of this process with the right equipment, expertise, and system integration. Let’s break down the main stages in the crushing process and how each step impacts overall performance.
1. Primary Crushing – Breaking Down the Big Stuff
The first stage in the crushing process is primary crushing, where large rocks from the quarry are reduced to manageable sizes. This is typically done with a jaw crusher or gyratory crusher, depending on the
hardness and size of the material. The goal here is to reduce the feed material to a size that can be handled by the secondary crusher.
Common Equipment: Jaw crushers (like the Metso C150), primary gyratory crushers
Typical Output Size: 6″ – 10″
2. Secondary Crushing – Refining the Material
After primary crushing, the material moves to secondary crushing, where further size reduction takes place. This is usually achieved with cone crushers or impact crushers, depending on the end product needs. The secondary stage helps shape the material and prepares it for final sizing.
Common Equipment: Cone crushers (such as the Metso HP400), horizontal shaft impactors
Typical Output Size: 1.5″ – 6″
3. Tertiary and Quaternary Crushing – Precision and Fines
For more refined products, operations may include tertiary or even quaternary crushing. These stages are especially useful in producing high-spec materials for asphalt or concrete. High-speed cone crushers or vertical shaft impactors (VSI) are often used in these stages to achieve the desired particle shape and gradation.
Common Equipment: High-speed cone crushers, VSI crushers
Typical Output Size: 0.25″ – 1.5″
4. Screening – Sorting the Final Product
Once material has been crushed, it is sent through screens to separate it into specific size ranges. Screening is a vital step to ensure each product meets spec. Oversized material may be sent back through the
crusher for further reduction, while on-spec material moves on to the next phase or to storage.
Common Equipment: Inclined screens, horizontal screens, scalping screens
5. Washing – Cleaning and Classifying
In some applications, especially when producing sand or stone for concrete and asphalt, washing becomes essential. Wash plants remove impurities like clay, silt, or dust, and help classify material by size. Mellott offers wash equipment from top partners like the McLanahan line of products.
Common Equipment: Log washers, classifying tanks, screw washers, dewatering screens
6. Stockpiling and Loadout – Ready for Use
Finally, the processed and screened material is moved into stockpiles and made ready for shipment or use on site. Proper material handling and loadout systems ensure the product retains its quality and is efficiently delivered to the end user.
Mellott: Crushing Process Experts
From turnkey systems to custom solutions, Mellott is your partner for each stage of the crushing process. Our engineering, fabrication, and field services teams work together to optimize plant design, maximize uptime, and improve productivity.
Whether you’re setting up a new plant or upgrading your current operation, our team is ready to help. Contact us here!
