5 Common Mistakes to Avoid in Gravel Crushing Operations

 Running an efficient gravel crushing plant requires proper planning, equipment selection, and maintenance. Many quarry and mining operators make avoidable mistakes that lead to downtime, higher costs, and poor-quality aggregates. Here are the top 5 mistakes and how to fix them.

1. Using the Wrong Crusher for the Material

❌ Mistake: Choosing a crusher based on price rather than material type (e.g., using an impact crusher for highly abrasive rock).

✅ Solution:
Soft to medium-hard rock (limestone, recycled concrete)? → Impact crusher (HSI)
Hard, abrasive rock (granite, basalt)? → Jaw + Cone crusher
Need uniform, fine aggregates? → Vertical Shaft Impactor (VSI)

✔ Tip: Test different crushers with your material before finalizing.

2. Overlooking Proper Feed Control

❌ Mistake: Dumping oversized or unevenly fed material, causing jams, wear, and inconsistent output.

✅ Solution:
Use a grizzly feeder or vibrating screen to remove oversized rocks before crushing.
Maintain a consistent feed rate—avoid overloading the crusher.
Train operators to monitor and adjust feed for optimal performance.

✔ Tip: Install level sensors in the crushing chamber to prevent blockages.

3. Neglecting Wear Parts Maintenance

❌ Mistake: Running jaw dies, blow bars, or mantles until they’re completely worn out, damaging the crusher.

✅ Solution:
Regularly inspect wear parts (check jaw plates every 50-100 hours).
Rotate or flip reversible parts to extend lifespan.
Use high-quality, abrasion-resistant materials (e.g., manganese steel for jaw dies).

✔ Tip: Keep a spare parts inventory to minimize downtime.

4. Ignoring Dust & Noise Control

❌ Mistake: Not implementing dust suppression, leading to health hazards, regulatory fines, and equipment damage.

✅ Solution:
Install water spray systems or dry fog dust suppression.
Use enclosed crushers or sound barriers to reduce noise pollution.
Follow OSHA/MSHA regulations for worker safety.

✔ Tip: Regularly clean crusher surroundings to prevent dust buildup.

5. Skipping Routine Maintenance & Lubrication

❌ Mistake: Running equipment without scheduled checks, leading to bearing failures, belt slippage, and unplanned downtime.

✅ Solution:

Follow the manufacturer’s maintenance schedule (lubricate bearings, check hydraulic systems).
Monitor oil temperature and contamination in crusher motors.
Inspect belts, pulleys, and electrical connections weekly.

✔ Tip: Use predictive maintenance tools (vibration sensors, thermal imaging) to detect early failures.

Conclusion: Optimize Your Gravel Crushing Operation

By avoiding these 5 common mistakes, you can:
✔ Reduce downtime with proper maintenance.
✔ Lower operating costs by minimizing wear and energy waste.
✔ Improve product quality with the right crusher and feed control.
✔ Stay compliant with environmental and safety regulations.

Need help optimizing your crushing setup? Let’s analyze your operation for better efficiency! Henan Baichy Machinery Equipment Co., Ltd. is a mining machinery manufacturer integrating R&D, production and sales. Stone crusher is one of its core production equipment. It has mature technology and processes, complete models and configurations, and technical engineers can tailor production line configuration plans for you. If you are interested in the stone crusher, please click on the online consultation to contact us. Baichy Machinery is dedicated to serving you 24 hours a day!