How to Automate a 200 tph Crushing Plant
For quarry operators in Saudi Arabia and South Africa, automating a 200 tph crushing plant reduces labor costs, improves product consistency, and increases safety. Knowing how to automate a 200 tph crushing plant involves selecting the right sensors, control system, and software to monitor and adjust crusher settings, feed rates, and screen parameters. Below we explain a practical automation roadmap and how OCP Mechanical Company supports your transition to semi‑ or fully‑automated operation.
Start with Basic Instrumentation
The first step in how to automate a 200 tph crushing plant is installing sensors on critical equipment. Key measurements include:
Crusher power draw (jaw, cone, VSI) – monitors load and prevents overload.
Closed side setting (CSS) for cone crushers – remote hydraulic adjustment allows real‑time tuning.
Belt scales on feed and discharge conveyors – measure throughput and detect blockages.
Screen amplitude and bearing temperature – predict maintenance needs.
Level sensors in bins and hoppers – control feeder speeds to maintain choke‑fed conditions.
OCP offers automation‑ready versions of our Type J jaw crusher, Type C cone crusher, and Type S vibrating screen, with pre‑installed sensors and actuators. Note: Product data are constantly updated; for the latest specifications of automation‑ready equipment, please contact our online customer service.
Many quarries in Riyadh and Johannesburg have started with power monitoring and remote CSS adjustment. This alone reduced manual CSS checks by 80% and improved product consistency.
Choose the Right Control System
The core of how to automate a 200 tph crushing plant is a programmable logic controller (PLC) with a human‑machine interface (HMI). OCP offers a modular PLC package that:
Starts and stops equipment in sequence – Ensures conveyors start in reverse order (from discharge to feed) to prevent material buildup.
Adjusts feeder speeds based on crusher power draw to maintain optimal load.
Monitors safety interlocks (pull cords, belt misalignment switches) and shuts down automatically.
Logs production data (tons/hour, power consumption, CSS) for shift reports.
The HMI can be a local touchscreen or accessible via web browser for remote monitoring. For a 200 tph plant, a basic PLC system typically costs $15,000‑$25,000, including sensors and installation. This investment often pays back within 6‑12 months through labor savings and reduced downtime.
The above values are for illustration only. OCP continuously improves its products. Contact our online team for the most current data sheet.
Many sand producers in Dammam and Cape Town have implemented PLC control, reducing operator headcount from 4 to 2 per shift while increasing plant availability by 10‑15%.
Add Advanced Features for Full Automation
For those wanting complete how to automate a 200 tph crushing plant, advanced features include:
Automatic CSS adjustment – A cone crusher can be programmed to maintain product size by measuring motor current and adjusting CSS every few minutes.
VSI rotor speed control – In a sand plant, rotor speed can be adjusted automatically to maintain target sand gradation using online particle size analysis (laser or sieve).
Remote monitoring and control – Supervise the plant from a central office using a VPN connection. Many suppliers offer smartphone apps for real‑time alerts.
Predictive maintenance – Vibration sensors and temperature monitors send alerts when bearings or gears exceed thresholds, allowing planned repairs.
OCP can supply a complete automation package tailored to your 200 tph line, from sensor installation to commissioning. Our engineers also provide remote tuning support.
As a direct‑selling manufacturer, OCP provides factory pricing on automation components, with no middleman markup. We ship to Jeddah, Dammam, Durban, or Cape Town ports within 20‑25 days.
Why OCP Is Your Partner for Plant Automation
Understanding how to automate a 200 tph crushing plant is just the beginning. OCP Mechanical Company has over 40 years of history in crushing and screening equipment. We offer:
Free pre‑sale automation audit to identify the most cost‑effective upgrades for your plant.
A customized PLC program based on your specific equipment and production targets.
24/7 online technical support for remote troubleshooting and software updates.
Our automation‑ready crushers and screens have been successfully deployed in automated plants across the Middle East and Africa. Customers often highlight the reduced labor, improved consistency, and economical price.
For a no‑obligation consultation and a personalized plan on how to automate a 200 tph crushing plant for your operation, simply click the live chat icon on this page. Our online customer service team is available 24 hours a day, 7 days a week, to answer your technical questions, provide free recommendations, and help you move toward a more efficient, safer crushing plant.
