The first real and productive jaw crusher development in 164 years

On 15 June, 1858, Eli Whitney Blake of New Haven was granted US patent No. 20 542 for a ‘machine for crushing stone’. A magnificent design that was well-ahead of its time. Since then, apart from small incremental improvements, the same basic design principle exists in all modern jaw crushers today. That was until now, and the development of the Hypro-Crush®.

One of the most expensive and important types of crushers is the primary jaw crusher and where high capacity is required, primary gyratory crushers. Both types are seen in use throughout the world generally, with gyratory crushers being selected by large quarries and mining operations. Although installation costs are often higher than their high purchase price and costly to operate, they have proved to be an essential item of equipment. In the main, the advantages of a jaw crusher make it essential due to its simplicity and ease of maintenance, with an effective installation cost making it a first-choice solution when it can reach desired capacity.

  © Moore Watson

© Moore Watson

New Hypro-Crush®

There has now been a real development with regards to mineral processing: the new high production jaw crusher Hypro-Crush®. This is a new global patent application and development comprising of a range of six models for different feed sizes that overcomes the problems inherent with traditional crushers. Due to the Hypro-Crush’s unique design and construction, the first four models to be introduced are commonly used feed size models and cover the spectrum of the full jaw crushing offering of major manufacturers. This has been achieved by using a development which uses less power and weighs significantly less, but still provides the productivity of established large crushers due to the unique designs.

The key development is that the Hypro-Crush® is much wider at the bottom than the top, thereby producing a highly efficient design providing the power to crush exactly where it is needed.  In effect, the Hypro-Crush® is a significantly smaller and lighter machine but has similar production of traditional designs. For example: the Hypro-Crush® TJ 10-14 is 1000 mm wide at the top and 1400 mm at the bottom and only weighs 19t but has the same productivity as a comparable 50 t unit manufactured by leading established crusher companies. Furthermore, it only requires 110 kW of installed power compared to 200 kW of the respective traditional machine. Due to its smaller size, it requires 40 % less power to start and run the machine and technical calculations have shown that it will produce in four days what a traditional crusher will do in five or six days. In addition to static installations, the smaller size will revolutionise the development of mobile tracked crushers.

The exact production figures and kW requirement for each model will be available after a further stage of testing.

  © Moore Watson

© Moore Watson

Less of everything but at least 20 % to 30 % more productive capacity

The Hypro-Crush® essentially uses less of everything to produce the output of much larger crushers. This delivers a major environmental as well as productive improvement as it goes a long way in helping to preserve the world’s fast diminishing resources. As the Hypro-Crush® is lighter and smaller, it uses less metal to manufacture, less power to operate, less power to build, less power to run – in fact less of everything. CO2 emissions are significantly reduced both in operations and manufacture. Due to the ability to run at a small CSS without a loss in production, the possibility also exists to remove a secondary cone from the production process resulting in less outlay.

Production at least matches traditional larger jaw crushers (or even exceeds at a narrow CSS) and is maintained due the wider exit for material at the bottom of the crusher. The top feed opening dimensions allow a smaller CSS to be set. It further enables a wider range of CSS to be used effectively. The Hypro-Crush® unique convex design wear plates have a ‘belly’ which will spread the material across the crushing chamber to utilise the full width of the lower jaws. A lip on the fixed jaw plate holds the material while being crushed and pushed through by the stroke and lip on the swing jaw plate, whilst tapered grooves located on the crushing wear plates are significantly wider at the bottom than at the top to greatly assist in the flow of material.


At the heart of the industry for over 60 years

The new design has been conceived based on over sixty years of hands-on global experience in crushing operations by Nicky Watson who has been, and still is, at the forefront of crushing operations for over half a century. His know-how has led to the Hypro-Crush®. This utilises many tried and tested features, but with a design geometry which expands the crushing path where it is needed most, thereby increasing crushing capacity without changing the reduction ratio or increasing power requirements. In fact, for a given operation, power savings can be made by selecting a smaller lighter (and therefore cheaper) machine for the same operation.

The Hypro-Crush® has been developed to not only transform static and mobile crushing installations but designed with a focus to deliver sustainability in the mineral processing industry. In order to deliver the world’s infrastructure it is essential that sustainable solutions are developed. The Hypro- Crush® goes a long way in helping the mineral processing industry meet sustainable and environmental targets through being more efficient, productive and requiring ‘less of everything’. In fact, the Hypro-Crush® is such a revolutionary development it effectively means that it will outperform all traditional Jaw crushers.

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