How to Increase Throughput of Existing Crushing Plant
For quarry operators in the Philippines and Peru, maximizing production from an existing crushing plant without major capital investment is a constant goal. Knowing how to increase throughput of existing crushing plant can boost your bottom line by 15‑30% with relatively low‑cost changes. Below we explain practical measures – from adjusting crusher settings to improving screening – and how OCP Mechanical Company supports your optimization efforts.
Optimize Crusher Settings and Feed
The first step in how to increase throughput of existing crushing plant is to review your current crusher parameters. A small change in closed side setting (CSS) can have a large impact:
Widen the CSS on primary jaw crusher – Increasing CSS from 120 mm to 140 mm on a Type J jaw crusher can increase throughput by 10‑15%, though product becomes coarser. If your secondary crusher has spare capacity, this is a quick win.
Reduce CSS on secondary cone crusher only if screen allows – A tighter CSS produces finer material but reduces throughput. Instead, focus on keeping the crusher choke‑fed. A partially empty crushing chamber reduces throughput by 20‑30%.
OCP recommends monitoring power draw: a cone crusher operating at 75‑90% of rated power is typically running at optimal throughput. Note: Product data are constantly updated; for the latest specifications of Type J and Type C, please contact our online customer service.
Many andesite quarries in Rizal and copper operations in Arequipa have increased throughput by 12‑18% simply by adjusting jaw crusher CSS and maintaining choke‑fed conditions.
Improve Screening Efficiency
A common bottleneck in how to increase throughput of existing crushing plant is the screen. If the screen cannot handle the load, recirculating load increases, reducing overall plant capacity. Here are practical fixes:
Increase screen area – Add a second screen in parallel or replace a single 1,800 x 5,000 mm screen with a 2,000 x 6,000 mm unit. This alone can boost plant throughput by 15‑25%.
Use high‑open‑area screen media – Polyurethane or woven wire with larger openings (e.g., replacing 5 mm with 6 mm) allows more material to pass, reducing recirculation. Monitor product quality to ensure specifications are met.
Adjust screen slope – Increasing slope from 18° to 22° increases material speed, reducing bed depth and allowing more throughput. However, efficiency may drop slightly.
OCP’s Type S vibrating screen offers adjustable stroke and modular panels. Many operators in Peru’s highlands have increased plant throughput by 20% after installing a second screen deck dedicated to fine material.
To master how to increase throughput of existing crushing plant, we recommend:
Conducting a screen efficiency test (measuring undersize in oversize). Aim for >90% efficiency.
Keeping screen panels clean with water sprays or air knives.
Reduce Recirculating Load and Downtime
Another key to how to increase throughput of existing crushing plant is minimizing recirculating load and unplanned stops:
Install a pre‑screen before the cone crusher – Removing fines below CSS reduces cone crusher wear and increases net throughput by 10‑15%.
Use a metal detector and magnetic separator – Prevents tramp iron damage that causes unplanned shutdowns. One hour of downtime at 200 tph costs 200 tons of lost production.
Optimize conveyor speeds – Ensure conveyors are not under‑belted. A belt running at 80% of rated capacity is safe; at 95%, spillage and downtime increase.
OCP’s direct‑selling model provides factory pricing on screens, magnets, and conveyor components, with no middleman markup. We ship to Manila or Callao ports within 18‑22 days.
Many aggregate producers in Luzon and Lima have increased overall plant throughput by 20‑30% by combining screen upgrades, pre‑screening, and routine maintenance.
Why OCP Is Your Partner for Plant Optimization
Understanding how to increase throughput of existing crushing plant is about small, targeted improvements. OCP Mechanical Company has over 40 years of history in crushing and screening equipment. We offer:
Free pre‑sale plant audit to identify bottlenecks (remote or on‑site).
A customized recommendation for screen media, crusher settings, and feed arrangement.
24/7 online technical support for implementation and tuning.
Our equipment has been successfully deployed in aggregate and mining projects across Southeast Asia and South America. Customers often highlight the practical advice, robust components, and economical price.
For a no‑obligation consultation and personalized advice on how to increase throughput of existing 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 get more tons per hour from your existing plant.
