Unlocking Productivity & Reducing Costs

In today’s coal processing environment, achieving optimal efficiency while controlling operational costs is essential for long-term competitiveness. With increasing demand for cleaner, more precise sizing, and the need to minimise waste and downtime, producers are turning to solutions that not only deliver on throughput, but also provide reliable, low-maintenance performance. Enter the multi-roll crusher.

Precision engineering for consistent, cubical output

At the heart of the multi-roll crusher’s appeal is its unique crushing technology. The intermeshing, continuous tooth roll design paired with precision roll timing enables exceptional control over product size. This is not just about meeting spec – it is about ensuring that coal and other friable materials are processed with minimal fines and optimal uniformity.

Compared to traditional impact crushers or hammermills, the multi-roll crusher offers up to 50% fewer fines, a significant advantage in coal preparation where fine particles often result in lost product value or higher disposal costs. The outcome is a steeper product size distribution curve, enabling more material to be sold, less to be discarded, and more efficient performance of downstream operations (such as screening).

A multi-roll crusher can accept large feed sizes – up to 1200 mm – and maintains throughput capabilities of over 6000 tph in the largest configurations. Whether operating in a surface mine, a coal-fired power plant, or an industrial processing plant, the ability to handle coarse feed and generate tightly controlled output adds measurable value to operational performance.

Designed for uptime: Ease of maintenance and tramp relief

Frequent maintenance and unscheduled downtime are leading cost drivers in coal handling. The multi-roll crusher mitigates both through its durable construction and operator-friendly maintenance features.

One of the crusher’s standout design elements is its coupling-mounted rolls, which allow rolls to be changed out without disturbing the main bearings – a task that can be completed by a two-person crew in as little as 8 – 12 hr for single-stage, and 12 – 16 hr for double-stage crushers. Split housing and roll removal rails further simplify disassembly and reassembly, minimising labour requirements and process disruption.

When uncrushable material enters the machine – a common hazard in coal environments – the Gundlach™ multi-roll crusher with Nitroil® Tramp Metal Protection System springs into action. This nitrogen/hydraulic adjustment mechanism absorbs the shock, prevents equipment damage, and returns the rolls to position automatically. It offers better protection than traditional spring systems and ensures longer equipment life, reduced component wear, and lower repair costs.

Lower power consumption = long-term operational savings

The multi-roll crusher is not only effective, it is also energy efficient. Thanks to its low roll speed and optimised tooth configuration, the machine consumes less horsepower per ton of material than competing technologies. In practical terms, this equates to power savings of 50% or more when compared to hammermills or high-speed impact crushers.

For coal operations with high throughput requirements, these energy savings compound quickly, resulting in significantly lower energy bills and improved environmental performance – an increasingly important consideration for facilities facing stricter emissions and energy use regulations.

Additionally, the unit operates at a steady-state horsepower significantly below its rated capacity, further improving overall energy efficiency. Operators benefit from reduced strain on electrical systems, longer motor life, and more predictable performance across varying loads.

 

This is a preview of an article that was originally published in the May 2025 issue of Global Mining Review.

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Read the article online at: https://www.globalminingreview.com/mining/30052025/unlocking-productivity-reducing-costs/