Efficiently Moving a Portable Crushing Operation

Relocating a portable sand and gravel crushing operation quickly, safely, and economically is one of the biggest challenges for producers. Over the years, advancements in design and technology have improved the process, but many operators still find it time-consuming, labor-intensive, and costly.

The Evolution of Portable Crushing Equipment

In the early days, portable sand and gravel processing equipment was bulky, expensive, and difficult to move. Each stage of the crushing and screening process required multiple conveyors to transfer material between components, making even a basic single-stage, 4-piece crushing spread a complex operation.

A simple setup with a feeder, crusher, screen, and power van (along with supporting conveyors and stackers) could easily require 10-15 pieces of equipment, translating to eight or more truckloads for relocation. Add in the labour, support personnel, and additional equipment needed to disassemble, transport, and reassemble everything, and it’s easy to see why a single move could take weeks.

The Hidden Costs of Moving

For crushing operators, the costs associated with moving a spread can be significant. Unfortunately, many operators assume they know the costs without fully analyzing the lost revenue, labour expenses, and potential savings. Keeping detailed records of these expenses can provide a clearer picture of the true costs of moving and reveal opportunities for cost reduction.

Calculating the Cost of a Move

Determining the cost of moving a crushing spread is straightforward when you consider the various factors involved, including:

  • Time: The time taken to disassemble, transport, and reassemble the spread.
  • Cash Costs: Expenses for equipment like cranes and trucks.
  • Labor Costs: Wages for the crew handling the move.
  • Lost Revenue: The downtime while the equipment is offline.

The more pieces of equipment you have to move, the more complex and costly the process becomes. Additionally, the use of cranes adds not only cost but also a higher level of safety risk for workers.

Reducing Moving Costs

Operators often assume that moving costs are unavoidable. However, there are several key questions worth considering:

  • Can the number of loads be reduced? Fewer loads mean less time, labour, and transportation costs.
  • Can we eliminate or reduce the need for cranes and other expensive support equipment? Minimizing the use of cranes can reduce costs and safety risks.
  • Can the overall plant design be simplified? Reducing the number of components that need to be disassembled and reassembled can lower both costs and complexity.

Solutions for a More Efficient Move

Since 1975, we’ve specialized in designing and manufacturing portable bulk processing equipment for the aggregate and mining industries. Our modular systems feature a common-level design with minimal loose conveyors, which simplifies site setup and minimizes the need for complex disassembly. By optimizing design, we help reduce the number of loads, the need for cranes, and the time spent on each move.