Key Factors to Consider When Setting Up a Stone Crusher Plant

Setting up a stone crusher plant requires careful planning to ensure profitability, efficiency, and compliance with regulations. Whether you're investing in a small 50 TPH plant or a large 500 TPH operation, these key factors will determine your success.

1. Site Selection & Preparation

✔ Location
- Near raw material sources (quarry, riverbed, or mining site) to reduce transport costs.

- Access to roads for easy movement of machinery and finished products.

- Avoid residential areas to minimize noise and dust complaints.

✔ Land Requirements
- Minimum 1–5 acres for a small-to-medium plant.

- Flat terrain with proper drainage to prevent waterlogging.

- Zoning permits (industrial/commercial land use approval).

2. Raw Material Quality & Availability

✔ Type of Stone
- Hard rocks (granite, basalt) → Require jaw + cone crushers.

- Soft rocks (limestone, sandstone) → Can use impact crushers.

- Recycled concrete/asphalt → Needs specialized crushers with pre-screening.

✔ Supply Stability
- Ensure consistent raw material supply (own quarry or reliable suppliers).

- Test material hardness (Mohs scale) to select the right crusher.

3. Crusher Plant Type: Fixed vs. Mobile

✔ Hybrid Option: Semi-mobile plants (modular design) offer flexibility + higher capacity.

4. Crushing Equipment Selection

✔ Primary Crusher
- Jaw Crusher (for hard rocks) – Models:  C106, PE900X1200

- Gyratory Crusher (for high-capacity mining).

✔ Secondary/Tertiary Crusher
- Cone Crusher (for uniform aggregates) – Models: HP300, CS75.

- Impact Crusher (for softer materials) – Models: PF1213,PF1315.

✔ Screening & Conveying
- Vibrating Screens (3–4 deck for grading).

- Belt Conveyors (B800–B1200 width).

5. Production Capacity & Output Sizes

- Plant Size Typical Output (TPH) Final Product Uses
- Small (50 TPH) 0-5mm, 5-20mm, 20-40mm Concrete, landscaping
- Medium (200 TPH) Road base, railway ballast Construction, infrastructure
- Large (500+ TPH) Quarry aggregates, mining Cement plants, export
Tip: Match production to market demand to avoid over/under-investment.

6. Environmental & Legal Compliance

✔ Permits Required
- Environmental Impact Assessment (EIA)

- Air & Water Pollution Clearance

- Mining License (if sourcing raw stone)

✔ Dust & Noise Control
- Water spray systems at crushing points.

- Enclosed conveyors & screens.

- Noise barriers for urban locations.

7. Power & Fuel Supply

✔ Electricity vs. Diesel

- Grid-connected plants → Lower operating costs.

- Diesel generators → For remote sites (higher fuel expenses).

✔ Energy Efficiency Tips

- Use variable frequency drives (VFDs) on motors.

- Opt for hybrid crushers (e.g., Sandvik QJ341+).

8. Labor & Operational Costs

- Role Workers Needed Estimated Monthly Cost (USD)
- Plant Manager 1 $2,000–$4,000
- Crusher Operators 2–4 $1,500–$3,000 each
- Maintenance Crew 2 $1,200–$2,500 each
- Total 5–7 $8,000–$18,000/month

Automation Options:

- PLC control systems reduce labor dependency.

- Remote monitoring for predictive maintenance.

9. Maintenance & Spare Parts

✔ Critical Wear Parts
- Jaw plates, cone liners, impact blow bars.

- Screen meshes, conveyor belts.

✔ Maintenance Schedule

- Task Frequency
- Lubrication Daily
- Belt tension checks Weekly
- Liner replacements Every 500–1,000 hours
Tip: Stock 3–6 months of spare parts to minimize downtime.

10. Budget & ROI Calculation

✔ Investment Breakdown
- Component Cost Range (USD)
- Crusher(s) $100,000–$800,000
- Screens/Conveyors $50,000–$200,000
- Land/Infrastructure $50,000–$500,000
- Permits/Legal $10,000–$50,000
- Total $210,000–$1.55M

Conclusion: Steps to Success

- Assess local demand and material availability.

- Choose fixed/mobile based on project duration.

- Select equipment matching rock hardness.

- Secure permits and environmental approvals.

- Optimize operations with automation/maintenance plans.

Need help designing your plant? Contact us for a free consultation.