Background
Mellott continually partners with customers to improve crushing efficiency, extend wear life, and lower operating costs. To quantify the real-world performance of Metso’s Long Life liners, Mellott conducted comparative liner scans on both Metso Long Life (LL) liners and a competitor liner set (ME) installed in the same HP400 crusher configuration.
Both liner sets were evaluated using 3D scanning technology to capture wear profiles, remaining material, and operational performance.
Metso HP400 Long Life Liners – Inspection Details
- Crusher Model: Metso HP400
- Chamber Type: SH M
- Bowl Liner: MM2039548
- Mantle: MM2039547
A used set of Metso Long Life liners was scanned to assess wear distribution, liner utilization, and remaining service life.
Competitor HP400 Liners – Inspection Details (ME)
A used set of competitor liners (ME) was also scanned for direct comparison.
- Crusher Model: HP400
- Chamber Type: SH M
- Bowl Liner: 1048300035 (Short Head Medium Bowl Liner)
- Mantle: 7055308387* (STD Fine Mantle)
The competitor bowl liner was identified as a Short Head Medium profile, while the mantle utilized a Standard Fine profile.
Performance Comparison
Operating Hours
| Hours | |
|---|---|
| Metso Long Life | 359 |
| ME Competitor | 230 |
| Improvement | +156% |
Days Installed
| Days | |
|---|---|
| Metso Long Life | 47 |
| ME Competitor | 32 |
| Improvement | +147% |
Hours Operated per Pound of Wear (as a Set)
| Hours/LB | |
|---|---|
| Metso Long Life | 0.10 |
| ME Competitor | 0.09 |
| Improvement | +110% |
Ending Worn Weight (lbs)
| Component | Metso LL | ME |
|---|---|---|
| Mantle | 1460 | 1420 |
| Bowl | 1260 | 1440 |
| Liner Set Total | 2720 | 2860 |
Key Findings
The scan data clearly demonstrates that Metso Long Life liners delivered:
✅ 56% more operating hours
✅ 47% longer installed life
✅ Higher hours per pound of wear, indicating improved material efficiency
✅ More consistent wear patterns across the crushing chamber
Despite starting with similar liner configurations, Metso Long Life liners achieved significantly longer runtime while maintaining strong structural integrity and effective chamber performance.
Customer Value
By choosing Metso Long Life liners supported by Mellott’s liner scanning and application expertise, customers can expect:
- Extended liner change intervals
- Reduced downtime and labor costs
- Lower cost per ton crushed
- Improved predictability in maintenance planning
- Greater return on wear-part investment
Key Takeaways
This comparative liner analysis reinforces the real-world value of Metso Long Life liners. With a 56% increase in operating hours, consistent wear patterns, and improved material efficiency, Metso Long Life liners clearly outperformed the competitor set, ultimately helping customers maximize wear life, reduce downtime, and achieve a lower cost per ton. Interested in bringing the benefits of Metso’s long life wear liners to your operation? Contact us today!
