Knowing the 4 Types of Crusher Spares Can Help Reduce Your Downtime

Whether your crushing spread is the backbone of a mining operation, producing road gravel for local municipalities, or creating plant mix for highway projects, extended downtime due to a lack of spare parts is a profit killer. A well-organized spares program is your best defence against unexpected and prolonged downtime. Even saving a few days of runtime over the course of a season can offset the cost of stocking critical parts.

The most common approach to a crusher spares plan involves categorizing parts into four main areas. The objective is to maintain an inventory of essential parts to minimize downtime, without tying up cash in unused stock. The four categories are as follows:

  1. Critical Spares
  2. Operational Spares and Consumables
  3. Capital Spares
  4. Service Tech Required

1. Critical Spares

Critical spares are commonly used parts that can fail unpredictably and are crucial for keeping operations running. These parts are usually used in multiple locations on a crusher and wear out regularly with little warning. When one of these parts fails, the resulting downtime can be both frustrating and costly. Examples include V-belts, bearings, conveyor components, toggle plates, and fasteners.

Key Takeaway: Critical spares should always be in stock and available on-site to prevent unnecessary downtime.

2. Operational Spares and Consumables

Operational spares and consumables wear out on a predictable schedule and are usually replaced during planned maintenance days. Extended downtime caused by these parts is often due to poor planning or miscommunication between operators, purchasers, foremen, and suppliers. Common examples include crusher manganese, screen cloth, and wear rubber.

Key Takeaway: These spares need to be readily available when needed. Proper planning, communication of lead times, and understanding of expected wear life are crucial to staying ahead of demand. Where these parts are stocked depends on various factors:

  • Central Stock: If multiple crushing spreads use common operational spares, it may make sense to keep central stock at your main shop.
  • Remote Locations: If the crushing spread is in a remote area, maintaining an onsite inventory is essential.
  • Smaller Operations: For smaller operations, consider discussing with suppliers what stock they can keep available for you.

3. Capital Spares

Capital spares require a significant investment and are rarely used. In most cases, you’ll have ample warning before these parts need to be replaced. Whenever possible, capital spares should be replaced in a dedicated repair facility to minimize exposure to the elements and prevent contamination of other parts. While field replacements are possible, logistics costs—such as shipping parts, tools, and manpower—can escalate.

Key Takeaway: Unless access to the site is extremely restricted (e.g., winter ice roads), capital spares don’t need to be stocked by the end-user until failure or planned replacement is imminent. Communication with suppliers is critical, as these parts may require a factory order due to limited stock availability.

4. Service Tech Required

There are parts that generally shouldn’t fail. Sometimes, a part is available, but it requires specialized repair or replacement that usually involves sending the entire piece of equipment to the factory or bringing in a service tech along with additional parts. Failures in this category typically occur due to:

  1. Catastrophic Events – e.g., a loader tooth seizing a cone crusher.
  2. End of Equipment Life – indicating a major overhaul or full replacement is needed.

Key Takeaway: Given the unpredictable nature of crushing operations, it’s impossible to plan for every scenario. However, identifying these parts can help you prepare for extreme situations that require more comprehensive solutions.

The Importance of a Well-Planned Spares Program

In the dynamic and often volatile world of crushing operations, no spares plan will cover every possible contingency. However, developing a structured, strategic spares program can dramatically reduce the impact of downtime. By categorizing and assessing your spare parts each season, you’ll find that each year your spares program will improve, compounding the returns on your investment of time and resources.

If you’re looking to create a more resilient operation, start by reviewing and updating your spares program regularly. Planning ahead will not only protect your productivity but also provide peace of mind, knowing you’re prepared for whatever challenges come your way.