Quarry production was out of balance with sales.
With the existing setup, the crushing plant was making too much dust and not enough 8-14mm.
The first issue was one of balancing the crusher settings to avoid stoppages due to mismatched crusher throughput. This improved the plant availability to 90% with process efficiency of 88%.
The optimum plant setup was then determined using process modelling and plant trials. The crusher settings and screen apertures were adjusted to regulate the circulating load and ensure continuous operation of the tertiary crusher. Belt samples taken from all machines confirmed the validity of the theoretical evaluation.
Following the changes, the site delivered an improvement in availability to 97.5% with 90% process efficiency. Production increased by 10% overall, with the desired product split, and an improvement to the P&L of €129k.