Technological Advances In Rock Crushing Machines

crushing site

The rock-crushing industry has experienced significant transformations in recent years thanks to technological advancements that have revolutionized how companies process and produce aggregates. These cutting-edge rock crushing machines are making it easier for businesses to achieve greater efficiency, reduce environmental impact and meet the growing demand for high-quality products.

Here are some of the latest technological innovations in rock crushers.

Artificial Intelligence (AI), Automation & PLC-Controlled Machines

One of the most significant breakthroughs in rock crushing machines is the integration of AI, automation technologies, and Programmable Logic Controller (PLC)-controlled machines.

PLCs are industrial computers used to control manufacturing processes and machinery offering enhanced precision, reliability and flexibility compared to traditional control systems. These systems enable machines to monitor and optimize crushing operations, increasing efficiency and reducing costs.

For example, the REMAX 600 track-mobile impact crusher developed by SBM Mineral Processing is a technological platform for an AI-based, fully automatic production monitoring and control system. The autonomous crusher improves efficiency and ensures optimum product quality and energy savings during the crushing process.

Hybrid & Electric Drives

As environmental concerns continue to take center stage, manufacturers are turning to hybrid and electric drives to power rock crushers. These systems offer reduced emissions and lower energy consumption compared to traditional diesel-powered equipment.

Kleemann’s Mobirex MR 130(i) PRO mobile impact crusher, for instance, features an E-DRIVE diesel-electric drive with an option for external power supply, enabling local emission-free operation. Similarly, RM’s H50X hybrid screen can run on diesel or fully electric modes, offering impressive modularity and versatility.

Advanced Sensor Systems & Video Technology

Incorporating advanced sensor systems and video technology into crushers allows for real-time monitoring and optimization of the crushing process.

The REMAX 600, for example, features a cutting-edge sensor system that assesses feed material and final products. As a result, the loading of the crusher and conveyor is improved while all the separation processes are optimized.

The data is sent to SBM’s headquarters via the cloud, where a digital twin compares the real machine data with thousands of stored reference data points to determine optimization potential, allowing for immediate and permanent adaptation of all process steps on-site without stoppages.

Enhanced Material Flow, Stockpiling & High Capacity

Modern rock crushing machines are designed to enhance material flow and stockpiling capabilities and deliver high capacity, ensuring consistently high utilization and productivity. The Kleemann PRO-Line system, for instance, can process up to 600 t/h of material thanks to its efficient pre-screening and continuous feed control.

The McCloskey J4 jaw crusher also boasts a large 1060mm x 700mm jaw opening, accommodating large feed sizes and contributing to higher production in material processing.

Another example of enhanced material flow is Terex Finlay’s C-1545P cone crusher, which features a direct variable clutch drive and an advanced electronic control system, providing efficient production and high material reduction ratios.

Intuitive Operating Concepts & Digital Solutions

As rock crushers become more complex, manufacturers are developing intuitive operating concepts and digital solutions to simplify their use.

For example, the Spective operating concept by Kleemann offers a large touch panel and two radio remote controls for easy operation of the Mobirex MR 130(i) PRO from the comfort of the excavator. Additionally, Spective Connect transmits important system data to the user’s smartphone, making reporting more convenient.

Improved Durability & Wear Resistance

Today’s rock crushing machines are built to withstand the most challenging conditions and deliver enhanced durability across various applications. McCloskey International’s J4 jaw crusher is designed for heavy-duty use in aggregates, construction and demolition recycling, and site preparation. The crusher features a robust design and enhanced material flow, ensuring high production and long-lasting performance.

Reversible Impact Crushers

Keestrack’s completely redesigned I4e tracked mobile reversible impact crusher features an advanced diesel-electric drive and can be used in secondary and tertiary crushing of rock, oversized gravel, and recycling building materials such as asphalt. The reversible impact crusher (RIC) technology offers the advantage of being able to process various materials, allowing for a more versatile and cost-effective solution compared to a traditional mobile cone or vertical impact crusher.

Energy Efficiency & Reduced Carbon Footprint

In addition to hybrid and electric drives, manufacturers are focusing on other ways to reduce the carbon footprint of rock crushers. For example, the RM Group’s hybrid crushers offer a 25% reduction in fuel costs compared to diesel-direct crushers or hydraulic screens.

When combined with the RM hybrid screen, the fuel savings can reach up to 50%, leading to significant environmental benefits and lower operating costs.

Enhanced Mobility & On-Site Flexibility

Despite their powerful capabilities, modern crushers are designed to offer enhanced mobility and on-site flexibility. McCloskey’s J4 jaw crusher is equipped with remote control tracks, allowing it to be easily moved and positioned on a project site. Keestrack’s I4e impact crusher also features a compact design and transport dimensions, making it highly mobile and easy to maneuver on-site.

Unlock The Full Potential Of Rock Crushing Machines With Mellott’s Expertise

Technological advances in rock crushing machines have significantly transformed the industry, rendering the process more efficient, cost-effective and environmentally friendly. From AI and automation to increased capacity and enhanced mobility, these innovations are changing how companies process and produce aggregates.

If you are interested in harnessing the potential of these technological advances for your business and want to make an informed decision, contact the experts at Mellott. Our team has the knowledge and experience to guide you through the process of selecting the best rock crushing machines to meet your unique needs. Contact Mellott today at 888.621.8533 or online to elevate your rock-crushing capabilities to new heights.