Comparing Cone Crushers: Sandvik Hydrocone vs. Top-Adjust Bearing Cones

The cone crusher is the backbone of most crushing spreads, essential for efficiently breaking down materials. Within this category, there are two primary families of cone crushers: the top-adjusting bearing cones and the bottom-adjusting bushing cones. For operators evaluating which cone crusher to invest in, understanding the differences between these types—especially in terms of production, maintenance, and parts costs—is essential. Here, we’ll dive into the specifics of two popular models: the Sandvik Hydrocone (Bottom Adjust Bushing Cone) and the JCI and Cedar Rapids Cone Crushers (Top Adjust Bearing Cones).

1. Design and Construction

The Sandvik cone crusher has a straightforward design with fewer moving parts. Supported at both the top and bottom, the head assembly is adjusted from below using a hydraulic piston. This simplicity in design often translates to easier maintenance and durability over time.

On the other hand, a top-adjust bearing cone is supported only at the bottom. To adjust the closed side setting, the bonnet (top of the cone) is rotated within a threaded support, a process that’s generally more complex and involves additional wear-prone parts.

2. Constant Liner Performance (CLP)

The bottom-adjust cone crusher (like the Sandvik) maintains a constant maximum feed size throughout the liner’s lifespan, offering consistent performance over time. In contrast, with top-adjust cones, the feed size reduces as the liner wears down, which may require adjustments or additional maintenance to ensure consistent output.

3. Adjustable Throw

The Sandvik cone crusher features an adjustable eccentric bushing, allowing operators to customize the throw of the head center/mantle. This flexibility helps optimize production rates and product shape, no matter the application. In comparison, bearing cones lack this adjustability, which can limit customization and optimization.

4. Chamber Configuration Flexibility

Sandvik cones offer a wide variety of chamber configurations, enabling precise adjustments for the desired size and shape of the final product. When combined with the adjustable throw, this flexibility makes Sandvik one of the most versatile crushers on the market.

5. Tramp Iron and Uncrushable Material Relief

Both types of cone crushers handle uncrushable materials differently:

  • Sandvik Cone: Equipped with the ASRi automation package, this crusher detects uncrushable objects by monitoring hydraulic pressure. If such an object is detected, hydraulic pressure is reduced, allowing the main shaft to lower and release the object. Once removed, the system automatically re-adjusts to the desired closed-side setting.
  • Top-Adjust Bearing Cone: When an uncrushable object enters, the hydraulic cylinders or springs holding the crusher open, releasing the object. However, the subsequent snapping back of V seats causes significant wear. In contrast, the Sandvik cone, which lacks V seats, experiences no such wear, leading to longer-lasting components.

Another advantage of the Sandvik cone’s tramp relief system is that its hydraulics are internal, reducing the risk of exposure and potential leaks. In top-adjust bearing cones, the external hydraulic lines are vulnerable to environmental factors and require regular maintenance.

6. Maintenance Cost Differences

Here are some key maintenance cost factors that set the Sandvik apart:

  • Threads and V Seats: The top-adjust cones, whether bearing or bushing types, have wear-prone threads and V seats. Every adjustment or uncrushable release causes these components to wear. The Sandvik cone, however, lacks these parts, reducing maintenance needs.
  • Rebuild Costs: If a major uncrushable object causes damage, repairing a Sandvik cone can cost significantly less than fixing a top-adjust bearing cone—sometimes up to 2-3 times less.
  • Field Maintenance: The Sandvik cone’s simpler design allows for most maintenance and repairs to be done on-site. This reduces the need to transport the crusher to a shop with cranes, saving time and expense.
  • Repair Complexity: Disassembly of the Sandvik cone requires fewer crane lifts, thanks to its straightforward design. There’s no need for heating or freezing (dry ice) during assembly, and all parts involve a simple lift, expediting inspections and repairs. The Sandvik also includes built-in lifting tools, making the maintenance process even more efficient.

Bottom Line

When comparing these two types of cone crushers, it’s clear that the Sandvik Hydrocone offers several advantages, from lower maintenance needs to greater flexibility and efficiency. For operators looking to minimize long-term costs and optimize production, investing in a Sandvik cone can be a wise choice. Consider how these differences in design, maintenance, and operational capabilities may impact your bottom line over the life of the machine.