Case Study: How a Quarry Doubled Output with a New Crusher?

When a leading granite quarry in East Africa struggled with stagnant output, frequent breakdowns, and spiraling maintenance costs, they faced a tough choice: upgrade or lose competitiveness. Here’s how a partnership with SHANGHAI SHIBANG MACHINERY (SBM) turned their operation into a regional benchmark—doubling throughput while slashing costs.

The Challenge: Bottlenecks & Burnout

The quarry’s aging jaw crusher couldn’t keep up:

• Output Plateau: Stuck at 200 t/h despite 24/7 operation.
• Chronic Downtime: Weekly liner replacements and motor failures.
• Energy Waste: Power consumption soared to 3.2 kWh/ton.
• Inconsistent Product: 40% of output failed to meet gradation specs.

“We were hemorrhaging money,” admitted the site manager. “Our crusher was a liability, not an asset.”

The SBM Solution: Precision Engineering Meets Smart Tech

After an on-site audit, SBM recommended deploying the C6X Jaw Crusher paired with the HPT300 Multi-Cylinder Hydraulic Cone Crusher—a combo designed for hard rock dominance. Key upgrades included:

? Adaptive Crushing Chamber: Auto-adjusting CSS (Closed-Side Setting) from 75–200mm to handle variable granite block sizes.

? Intelligent Load Detection: Sensors prevented overloads by instantly adjusting feed rates.

? Anti-Wear Arsenal: Tungsten carbide liners and a reinforced main frame for abrasive conditions.

? Energy Recovery System: Regenerated 15% of power during idle cycles.

“What sold us was SBM’s AI-driven optimization platform,” said the quarry’s lead engineer. “It didn’t just crush rock—it learned our operation.”

The Transformation: Numbers Don’t Lie

Within 3 months of installation:

• ? Throughput Doubled: From 200 t/h to 410 t/h, surpassing KPIs.
• ?? Energy Efficiency: Consumption dropped to 2.1 kWh/ton—a 34% reduction.
• ?? Maintenance Wins: Liner lifespan increased from 7 to 28 days.
• ?? Product Consistency: 95% of output met ISO gradation standards.

But the biggest win? The site reduced operating costs by $280,000 annually—funding an expansion into new markets.

Behind the Scenes: How SBM’s Tech Made It Possible

1?? Pre-Screening Mastery: The quarry added SBM’s YKN3X Vibrating Screen to pre-sort feed, ensuring blocks ≤650mm entered the C6X crusher—eliminating jams.

2?? Smart Crushing Logic: The HPT300 Cone Crusher’s AI Predictive Setting Adjustment analyzed rock hardness in real time, tweaking eccentric speed and CSS to maintain optimal pressure.

3?? Remote Monitoring: SBM’s Cloud-Based Platform alerted the team to wear patterns, scheduling maintenance during low-demand shifts.

The Ripple Effect

The upgrade didn’t just boost output—it reshaped the quarry’s business:

• Won contracts for high-spec railway ballast projects.
• Reduced carbon footprint by 22% (thanks to energy-efficient drives).
• Scrapped plans for a second production line—the new crushers did the work of two.

Lessons for the Industry

• ?? Automation Isn’t Optional: Real-time adjustments are critical for hard rock.
• ?? Invest in Lifespan: Durable liners and smart wear tracking save millions.
• ?? Think Beyond the Crusher: Pair with SBM screens and conveyors for a seamless flow.

Ready to Rewrite Your Quarry’s Story? Whether it’s granite, basalt, or iron ore, SBM’s crushing solutions are built to outperform, outlast, and outthink.

Have a bottleneck to bust? Let’s chat—comment below or DM us!

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