Local manufacturer perfects cone crusher performance

23rd October 2022


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Motion plastics producer igus South Africa has helped crushing equipment manufacturer Crush Force perfect its two-foot cone crusher, developed to offer a superior alternative to traditional machines, through the replacement of one component.

Crush Force designer and founder Leon Venter experienced repetitive, unexpected failures of a seemingly insignificant bush on a test machine that was being trialled at a hard metal recycling operation near the company’s East Rand factory, in Gauteng.

“The 45 mm bush serves as a guide for the torque arm. Phosphor bronze and several other materials all failed prematurely within a few weeks. In each instance, the entire processing line needed to come to a halt for the part to be replaced,” explains Venter.

Despite finite element analyses, stress tests and a host of other interventions taken during the ongoing development of the crusher, no material could stand up to the stresses exerted on the small bush until igus South Africa brought engineered plastics into the equation.

“igus polymer specialist Juan-Eric Davidtz suggested that we use one of the company’s specially formulated bushes. Having previously used igus materials for other components, I installed the bush on the crusher about a year ago and it is still in operation to this day. On inspection, it is clear that the bush is holding up well and shows no visual signs of wear and tear,” adds Venter.

The bush is made from igus’ iglide material and offers exceptional technical and economic advantages over all types of metal plain bearings (bushes) and enables the crusher to perform at its design capability.

The bushes are also self-lubricating, maintenance-free, chemical resistant, universally applicable and reduce costs by up to 40%, highlights Davidtz.

igus bushes can withstand extreme temperatures, are self-lubricating and are suitable for special machine construction, underwater applications and harsh conditions such as minerals processing and mining, he says.

“We also have a range of standard catalogue options and can customise solutions where necessary.

“This makes upgrading of existing bushes simpler and as with Crush Force, our customers can increase their technology and reduce their costs by up to 90%. In addition, customers benefit through fast lead times, online service-life calculators and tools for nearly all product lines.”

Venter emphasises his frustration with the repeated bush failure, as all the other components comprising the cone crusher are designed to ensure that it outlasts and outperforms ordinary crushers.

“The torque arm bush was the last piece of the puzzle to produce South Africa’s own, world-beating cone crusher.”

Crush Force set out to manufacture the world’s most productive crusher for hard rock applications from the onset. 

“Every part has been designed and redesigned with endurance and performance in mind to take on the tough hard-rock mining conditions in Southern Africa and now that we have ironed out even the smallest of problems, we are set to take on the mining world,” says Venter.



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