Basic Process and Operating Procedures for Crushing Operations

Basic Process and Operating Procedures for Crushing Operations

Crushing operation is a systematic engineering process that transforms large blocks of stone into construction aggregates or industrial raw materials that meet specifications. Following a clear basic process and strict operating procedures is fundamental to ensuring production safety, improving efficiency, controlling costs, and guaranteeing product quality. The entire operation can be summarized into four main stages: preparation, crushing, screening and conveying, and finishing. Each stage has its own essential operating points that must be followed.

Stage One: Pre-operation Preparation and Equipment Inspection. This is the starting point for all safe and efficient production, and the core lies in "thoroughness" and "prevention." Before operation, the site must be cleared to ensure there are no obstacles or unauthorized personnel around the equipment. Operators must conduct a comprehensive inspection of the equipment: check that all connecting bolts are tightened; check that the lubrication system oil level is normal; check that the belts are in good condition and properly tensioned; check the inside of the crushing chamber to ensure there are no foreign objects, especially metal parts or other uncrushable materials left over from the previous operation. At the same time, the crusher's discharge opening size should be adjusted in advance according to the target finished product specifications. All personnel must wear appropriate personal protective equipment, such as safety helmets, dust masks, work clothes, and non-slip safety shoes.

Stage Two: Starting, Feeding, and Crushing Operations. This is the core of the process, and the key is "no-load starting, uniform feeding, and stable operation." The equipment must be started strictly in the order of "starting downstream equipment first, then upstream equipment." For example, start the finished product conveyor belt first, then the screening equipment, and finally the crusher main machine. After all equipment has been running idle for 1-2 minutes, and after confirming that there are no abnormal sounds or vibrations, uniform and continuous feeding can begin. During feeding, the material flow must be controlled to ensure even distribution across the width of the crushing chamber, and exceeding the equipment's maximum processing capacity is strictly prohibited to prevent blockage or overload. During the crushing process, operators should monitor the operating status by observing the ammeter and listening to the equipment's sound. If abnormal noises, violent vibrations, or a sudden increase in current are detected, the machine must be stopped immediately for inspection.

Stage Three: Screening, Conveying, and Finished Product Storage. The crushed mixed material usually needs to be classified through screening equipment (such as a vibrating screen). The procedures require regular inspection of the screen mesh to ensure it is intact, without damage or blockage, and to ensure accurate classification. The finished materials at each stage are transported to different stockpiles by corresponding conveyor belts.  It is essential to ensure that the stockpiles are neatly arranged, with safety slopes maintained to prevent collapse. Throughout the entire conveying process, personnel are strictly prohibited from crossing or standing under the conveyor belts, and it is strictly forbidden to touch the running belt rollers and idlers with hands or tools. All transfer points should be equipped with necessary dust control and protective covers.

Fourth stage: Shutdown, cleaning, and maintenance. After the operation is completed, the shutdown sequence is the reverse of the startup sequence, i.e., "stop upstream first, then downstream." The crusher must be completely emptied of material, and all material on the conveyor belts must be transported before the equipment can be shut down stage by stage. After shutdown, the inside and outside of the equipment, especially the crushing chamber, screens, and the area under the conveyor belts, should be thoroughly cleaned. The wear condition of wear parts should be inspected and recorded. Any problems found and maintenance performed should be recorded in the shift handover log or equipment log. Following this closed-loop process and procedures from preparation to completion is the fundamental guarantee for safe, continuous, and efficient crushing operations.