Choosing a mobile impact crusher is a critical decision for any recycling or demolition operation. To ensure you choose the right screening equipment that fits your needs and budget, here are ten essential questions to guide your purchase.
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Identify the type of material you will process, such as concrete, asphalt, or natural rock, and calculate projected costs per ton for running the crusher, including fuel, wear parts, and maintenance. Also be sure to estimate the amount of raw material and define the desired end-product size and quality. Understanding these factors helps determine the machine's capacity and suitability.
While compact crushers, impact crushers, and cone crushers are used on the first pass in many applications, a secondary tool like a jaw crusher can also be necessary to break apart abrasive material into even finer sizes. Ensure that the crusher you select can produce the desired output size.
Consider local environmental regulations on noise, dust, and emissions where the crusher will operate, especially when crushing concrete or other potentially toxic waste materials. Check if electric power is available and cost-effective compared to diesel. Electric or hybrid models might offer environmental and operational advantages in certain settings.
Pay attention to engine horsepower, rotor weight, and blow bar size to understand crushing power. Evaluate hopper capacity, feeding height, total machine weight, and dimensions, and confirm the machine can be transported easily within your fleet and job sites.
Is it direct from the engine, electric, or hydraulic? Each option comes with its own trade-offs in terms of power, fuel use, and maintenance. Think about what fits your workflow best — do you want simplicity, efficiency, or flexibility in your aggregate or concrete crusher?
Some impact crushers can track while crushing, which is a game-changer on active job sites. If you're constantly repositioning equipment, this feature can save serious time and hassle.
If you're running a jaw upfront or a screen plant downstream, make sure your impact crusher plays nicely with the rest of the system. Smooth material flow through the crushing chamber is key to keeping production moving and avoiding bottlenecks.
Would a built-in screen make your life easier? How about a magnet for rebar or an extended conveyor? Don't overlook the value of integrated systems. They can make your setup more compact, efficient, and easier to manage.
Quality parts matter. Take a good look at the blow bars, rotor, hydraulics, electronics, and even the steel used in the frame. Cheap components will cost you more in the long run through wear, breakdowns, and downtime.
Quick, hassle-free maintenance keeps production moving. Look for a design that allows easy access to service points and fast blow bar changes. Less downtime means more tons crushed and fewer headaches on site. Be sure to also consider the amount of operational costs that might be needed to maintain the right crusher.
Even the best machines need service. Ask how quickly you can get replacement parts and what the local support looks like. If a critical part goes down, you want to be back up and running fast.
Asking these kinds of practical, job site-focused questions will help you find a mobile impact crusher that doesn't just tick boxes, but actually delivers on your day-to-day needs.
Horizontal Shaft Impactor (HSI) is a type of heavy machines works to crush the rocks, stones, concretes, asphalts or other objects which need to be size reduced for preparation of next procedure in quarry, mining, cement, construction industry.
HSI impact crusher mainly consists of a motor, a rotor, aprons, impactor housing and blow bars. Working principle of a impactor is the motor drives the horizontally mounted rotor as well as the blow bars which are mounted on the rotor rotating at very high speed. The objects feed from the open inlet of impactor are hit by the blow bars towards the impact plates which are mounted on the aprons and bounced back. The objects are shattered and size reduced during this process and discharged from the outlet of impactor.
Blow bar is the key and largest wear part on impactors. As the rotor runs at very high speed, blow bars withstand huge shock and sever abrasion from the crushed objects. Blow bars are the most frequently replaced wear parts and account for a big part of operation cost of impactor. Making the blow bars works longer is so crucial to keep the impactor run time and cost efficiently.
Any failure with the blow bars costs a high lost on time and money. A good blow bar should not only last as long time as possible but also works safely without breakage. That means the blow bar must have good resistance to wear and enough resistance to impact at the same time. How to make the blow bars last longer? The answer is on the materials that blow bars are made of and the foundry where it is made by.
The crushing applications are always various due to the different natures and different sizes of crushed objects. To have the best performance in different applications, blow bars are normally made in following materials to have different natures in terms of wear and impact resistance.
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Manganese steel
Manganese steel is a kind of austenitic steel with around 13% or 18% content of Manganese. It is featured with very good impact resistance but low wear resistance. Manganese steel is the first option for blow bars which used on primary or second crushers with large feed size, usually over Dia. 800mm, or applications with high content of unbreakable objects come into the impactors. A typical application of manganese blow bars is crushing the limestones in quarry plants of cement plants.
Manganese steel with Titanium Carbide (TIC) columns inserted
Due to the nature of low wear resistance of manganese steel, Titanium Carbide columns (TIC) are sometimes inserted into the wear face of manganese steel blow bars to increase its wear performance. With TIC inserts, service life of manganese blow bars could be up to 60% increased but the cost of blow bars is higher.
Martensitic alloy steel
Martensitic steel is a type of alloy steel with Molybdenum, Nickel and other alloy ingredients in its compositions. It is featured with better wear performance than manganese steel but impact performance is compromised. This nature enables martensitic blow bars to achieve better wear life in applications where the feed size is smaller or a little content of unbreakable objects contaminated. A typical application of martensitic steel blow bars are used on impactors recycling the concretes with rebars content.
Martensitic alloy steel with ceramic inserted
To obtain longer wear life of martensitic steel blow bars, industrial ceramic grits could be inserted in the martensitic steel matrix of wear areas. Thanks to the excellent wear performance of ceramics, the martensitic steel blow bars could have 100% longer wear life. However, the cost of blow bars is about 50% increased with the ceramic inserted.
Chrome white iron
Chrome white iron has higher content of carbon and chromium than manganese steel and martensitic steel, which gives chrome white iron blow bars outstanding wear performance but very low impact resistance. Chrome white with about 20% content of chromium is normally named medium chrome and around 25% is named high chrome. Blow bars made of chrome white iron are the first option for impactors crush very abrasive rocks on secondary or tertiary crushers. The size of rocks feed into the impactor must be strictly controlled, usually less than dia. 300mm, and any unbreakable objects or iron tramp is NOT allowed in feeding. A typical application of chrome white iron blow bars is used to crush natural stones or granites in aggregates or sand-making plants.
Chrome white iron with ceramic inserted
To further obtain longer wear life of chrome white iron blow bars, ceramic grits are also inserted at the wear areas. The wear life of chrome blow bars could be 100% increased but cost is also about 50% increased. Furthermore, Sunwill has special grade chrome ceramic blow bars in C650 grade, which is able to achieve up to 170% increase on wear life in very abrasive secondary or tertiary crushing applications.
All blow bars are originally made in foundries. A good foundry will not only provide the good and reliable quality of blow bars, but also be able to provide versatile and innovative solutions for specific applications at metallurgical basis.
Sunwill Machinery is a foundry with over 15 years’ experience in the manufacturing and service of blow bars. Sunwill Machinery is able to provide all above materials suits different applications, also the metallurgists and engineers know how to make the blow bars right for customer’s specific applications.
Please visit Sunwill Machinery at www.sunwillmachinery.com or drop an at when you have any questions about the blow bars for impactors or need a site specific solution. We are happy to assist at any time.
Other topics about Sunwill Blow Bar
Part 1:Blow bars selection guidance and Impactor brands list
Part 2:How to make a good blow bar
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