How to Increase the Capacity of Aggregate Plants

As the concrete aggregate market continues to heat up, many quarry operators have begun to consider upgrading aggregate production lines to increase the production capacity of sand and gravel. So how to transform the crushing line with the minimum cost to maximize profit?

Generally, it can be divided into 3 transformation steps:


Reasonable optimization of the existing crushing production line is the most reliable solution.

The optimization of the crushing production line is mainly reflected in two aspects:

1, Optimize the crushing cavity

According to the characteristics of the crushed materials, the wear-resistant liner of the crushing chamber is optimized.

According to the working conditions of the crusher, replacing the liner with higher wear resistance can effectively reduce the downtime of the crusher, increase the output of the crushed stone aggregate and further improve the gradation of the aggregate.

2, Optimize the crushing circuit of the plant

In addition to the crushing cavity, optimizing the entire crushing circuit is a good overall planning method to increase production. To understand how the entire loop operates as an independent process, two points need to be judged: where the system bottleneck and the available capacity are. Once bottlenecks and sections with additional capacity are found, solutions to eliminate bottlenecks and utilize additional capacity need to be proposed.

For example, if the intermediate crusher is determined to be the bottleneck, and the fine crusher has idle capacity, the sieve hole diameter of the inspection and screening can be increased to make the coarse material enter the next process faster.

Overall, this solution redistributes workloads to equipment with greater capacity. However, every process adjustment (including changes in blasting technology and pre-concentration strategies) will have an impact on other processes, and it is necessary to ensure that the processes work together in the best way.


Process optimization will be limited by the existing crushing equipment. If your crusher is an old model and the design capacity is limited, you can consider upgrading the equipment.


Upgrades can help increase annual production by reducing downtime. For example, the old model may not have an effective iron-pass release function, which leads to excessive downtime and high maintenance costs. If it is upgraded to a hydraulic iron-pass release and cavity cleaning system, it can ensure rapid recovery of operation. Upgrading is a good way to bring equipment back to life, and the cost is small, and there are many options.

Other upgrade projects can also achieve faster discharge opening adjustments in order to maintain consistent production and reduce cycle load. Upgrading the crusher to the latest features and technologies can increase production and be accompanied by many benefits, such as more convenient maintenance and improved safety.

Special attention is that the upgrade can solve many problems, but if the upgrade does not solve the system limitations, the problem will not be solved, and new problems may appear.


Technology is constantly improving, and the crusher is no exception. The new generation of crushers can significantly improve the crushing capacity, final product gradation, and crushing ratio, and can better control the width of the feed opening when adjusting the crusher’s discharge opening. In addition, downstream equipment such as vibrating screens, conveyors and mills may also benefit. If you have an extra budget, replacing it with the latest crushing and screening equipment will greatly increase the production capacity of crushed stone aggregates.

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