Sunday, July 14, 2024

Cover Story June 2024

Cover Story June 2024

Rising consumer awareness owing to the inherent benefits such as flexibility, mobility, and on-site processing capabilities, has been immensely contributing to the market growth of crushing & screening equipment lately. Moreover, the implementation of supportive regulatory policies by several governments across the globe to encourage the use of recycled materials in construction is favouring the market growth. With the fast paced technological advancements, these machines are also set for a huge transformation just like other construction equipment and play a key role in the holistic growth of the sector…. writes, PRERNA SHARMA.

The market for crushing, screening, and mineral processing equipment is a vibrant industry sector, essential to the mining and construction industries worldwide. A significant portion of this market is made up of crushing equipment, which includes devices made to break down big raw materials into smaller, easier-to-handle particles. Jaw crushers, cone crushers, and impact crushers, among others, are essential for crushing a wide variety of materials, from harder minerals to softer rock. Another crucial component is screening equipment, which is gear used to separate particles according to their size or other physical characteristics. To ensure the manufacture of consistent and superior final goods, materials are graded using screens, sieves, and separators. This procedure makes it possible to isolate materials of particular sizes for additional processing or use, which is essential for a number of industries, including mining, building, and recycling. Technological developments and changing industry demands are driving dynamic shifts in the Crushing, Screening, and Mineral Processing Equipment Market. The landscape is changing as a result of advancements in automation, data analytics, and sustainability initiatives that promote environmental responsibility and efficiency. Manufacturers are proactively adjusting to suit the changing demands of the mining and construction sectors as the market adopts these trends.

Automation and Smart Equipment: Automation in the sector is booming, with machines utilizing AI, machine learning, and sensors for better processing efficiency, predictive maintenance, and self-optimization. This lowers downtime, increases safety, and decreases manual intervention.

Sustainable and Environmentally Friendly Solutions: Equipment designed to limit energy use, reduce emissions, and facilitate resource recovery is becoming more and more in demand due to environmental restrictions and increased public awareness. Water-efficient processing techniques and hybrid electric crushers are examples of green technology that are becoming more popular.

Customization and Modular Designs: Players in the market are progressively providing specialized equipment solutions made to fit particular requirements and applications. Because of their versatility, modular designs make it easy to expand and adapt as business needs change.

According to Mordor Intelligence, the Mobile Crushers and Screeners Market size is estimated at US$3.10 billion in 2024, and is expected to reach US$4.08 billion by 2029, growing at a CAGR of 5.68% during the forecast period (2024-2029). Mobile crushers and screeners are a form of stationary crushers and screeners, which are mounted either on wheels or on tracks. They are emerging crushing equipment, showing high potential for growth over and beyond the forecast period. As these rock-crushing machines are easily movable on and between production sites, their demand has witnessed continuous growth in mining operations, aggregates production, recycling, and applications across several other end-user industries.
A significant factor driving the growth of the market is the growing demand for reduced transportation and fuel costs, as mobile crushers can be easily transported and installed at places intended to be used for a short period. The cost efficiency of mobile crushers increases proportionally to the routes to the crushers and the distances in the quarries, which influences the overall operational cost, thereby driving their adoption.
In recent years, the capabilities of mobile crushers have also expanded significantly owing to the technological developments developing their use cases. For instance, mobile crushers and screeners are increasingly finding applications in open pit mines. Hence, the increasing mining activities across various regions are also anticipated to create a favourable outlook for the studied market’s growth during the forecast period.
Mobile crushers are dominating the market as they process the material on-site, thus reducing the need to transport bulky, unprocessed rocks and ores. Furthermore, they are designed for heavy-duty operations and can handle large-sized materials that are found in mining and major infrastructure projects. Their high capacity makes them a cost-effective solution for large-scale operations. Additionally, the recent technological advancements to increase the efficiency and productivity of mobile crushers are boosting the market growth. Moreover, the integration of automation, global positioning system (GPS) tracking, and remote diagnostics, which improves operational efficiency and enhances worker safety, is positively influencing the market growth. Besides this, mobile crushers are compatible with various types of screening equipment, which allows more versatile applications and comprehensive processing operations. In addition, the growing focus on sustainability and reducing carbon footprint has heightened the use of mobile crushers, as they facilitate on-site recycling of construction waste.
The growing demand for mobile crushing and screening equipment encourages vendors to launch innovative solutions. Vendors are also focusing on integrating advanced technologies, such as automation and IoT, to enhance the capabilities of these devices. For instance, in August 2023, the Wirtgen Group introduced its latest model of mobile crushers, the MOBIREX MR 100(i) NEO/NEOe. The crusher is an all-electric machine designed to operate in confined areas on construction sites. The spectrum of operations includes soft to medium-hard natural stone processing and various recycling applications, including processing debris, concrete, and asphalt.
The Powerscreen Metrotrak is a highly compact, high performing tracked mobile jaw crushing plant featuring the “M” series single toggle jaw crusher. The new Metrotrak builds on the previously successful model with upgraded features, additional options, and slick new styling. It includes an aggressive crushing action and a high output even in tight settings. The Metrotrak is ideally suited to operators in the mining, quarrying, and recycling industries; especially those working in urban locations or where space is restricted.
The new Metrotrak builds on the previously successful model with upgraded features, additional options and slick new styling. With a hydraulically adjusted, fuel efficient direct drive chamber as standard, users benefit from an ability to quickly and easily change the size of finished product with minimal running costs. To maximize return on investment, machine uptime requirements are at an all-time high and operators demand a machine which is easy to service and maintain. The Metrotrak offers exceptional maintenance and access via centralised hydraulics and electrics, a newly designed bypass chute with excellent internal access and platforms.
The most recent Powerscreen® Hybrid range has been designed to give customers alternative energy options to operate their range of crushing, screening, and conveying equipment. These hybrid machines have been dramatically enhanced to include more fully electric crushers and screens, as well as models powered by innovative combinations of diesel and electricity.
Overall, the growing demand for compact and versatile crushers and screeners across various industries and the expanding use cases of mobile crushers and screeners are anticipated to continue to drive the market’s growth during the forecast period.

The Global Cone Crusher Market size is estimated at US$1.86 billion in 2024, and is expected to reach US$2.38 billion by 2029, growing at a CAGR of 5.10% during the forecast period (2024-2029). The crushing and grinding requirement of industries, such as mining, construction, processing, and demolition, changed drastically in the last two decades, where crushers were primarily stationary equipment that was used to convert coarse materials to more elegant materials, and eventually, pass them onto the tertiary crushing equipment. Nowadays, the demand for mobile and portable crushers is observing significant growth.
Industries that operate crushing equipment are focusing on lowering costs, increasing production, and becoming more energy-efficient, as crushing equipment is a primary reason behind increased energy consumption in these industries. For instance, ammunition consumes the most significant part of the energy used in mining operations, of about 30-70%. According to Thermo Fisher, grinding and crushing of ore are energy-intensive and account for about 3-5% of the world’s power usage. Owing to this, various vendors in the market are increasingly offering solutions that are energy efficient and save costs.
New cone crushers that operate with hydraulic hold-down clamping enable industries to crush at a higher capacity with increased power than ever before. The automatic control of cone crushers has maximized power draw and their throughput, owing to which vendors in the market are focusing on increasing the capacity of their offerings. For example, the Nordberg HP900 series cone crusher from Metso comes with a new lubrication system, improved kinematics, a raised pivot point, and increased power to offer a 15% increase in its capacity. The increased size provides increased production and output in the mining industries, where production capacity and throughput are vital.
The application of cone crushers in construction work and road laying material is significantly rising. With the growing concept of recycling, current crushers can separate bitumen and aggregates for reuse as new asphalt. New asphalt stations can create a unique asphalt mix with up to 70% recycled material, and various businesses are deploying cone crushers, along with jaw crushers, to enhance the speed and capacity. For example, Veljekset Paupek, based in Tornio, Finland, adopted the Lokotrack LT200HP cone crusher and the Lokotrack LT106 jaw crushing plant to create a two-stage crushing process. This enabled it to crush an entire batch of 10,000 metric tons in just two weeks.
The Sandvik cone crusher design philosophy is based on continual evolution of parts, materials, and technologies to improve the reliability, availability, and productivity our customers rely on. That commitment has led to the latest in its industry-leading advances in connected crushing – the upgraded 800i cone crusher range with new ACS-c 5.
“The upgraded 800i crushers with new ACS-c 5 are a natural next step in setting the bar for crushing. Their ideal combination of high crushing forces, reliability and simplicity make them easier to operate, manage, maintain and service—leading to productivity and uptime gains that are gamechangers for operational performance.” Javier Valdeavellano, Lifecycle Manager 800i cone crushers.
The latest 800i crushers with new ACS-c 5 combine simple yet robust mechanical design with powerful user-friendly automation to better support diverse operational roles. Having access to operational insights, combined with simplicity and reliability ensure the team’s ability to run a smooth operation while reaching their targets.
Simplicity of mechanical design is key to maximum reliability and availability. Sandvik 800i crushers have evolved with new mechanical and automation advantages that simplify service and troubleshooting, improve safety, and optimize performance while minimizing downtime.
Puzzolana launched bigger sized cone crushers PFSC 120 and PCC33150 which come with fixed and floating functions designed to enhance the capacity and productivity of the crushing units. The Track Plants are offered with both fixed and floating shaft Cone Cruhsers with capacity up to 350TPH. The fixed shaft crushers can optimize the crushing plants since they can produce smaller size products. The company also recently showcased its new asphalt road paver that can pave up to 10 meter width roads. For higher performance of its crushing and screening plants and predictive maintenance, Puzzolana is working towards digitalizing its crushing and screening plants.

Stone Crusher Market size was valued at US$6.34 billion in 2023 and is expected to reach US$12.9 billion by the end of 2030 with a CAGR of 7.4% during the forecast period 2024-2030, according to Verified Market Reports. Manufacturers in the stone crusher market are constantly innovating to develop crushers that are more efficient and sustainable. This includes advancements in crusher design, such as improved crushing mechanisms and integrated dust suppression systems. Additionally, the focus is shifting towards automation and digitalization, with features like remote monitoring and data-driven optimization gaining traction. These advancements not only enhance crushing efficiency and productivity but also contribute to a more environmentally friendly operation. The stone crusher market is seeing a growing preference for mobile crushing plants. These self-contained units offer greater flexibility and convenience compared to traditional stationary crushers. They can be easily transported and deployed at various crushing locations, eliminating the need for extensive setup and infrastructure. This mobility is particularly beneficial for construction projects requiring crushed stone at multiple sites or for remote mining operations.
The mounting environmental concerns have surged the need to repurpose construction waste into usable materials. Stone crushing equipment plays a pivotal role in breaking down large rocks into smaller fragments to cater to uses in recycled construction materials while promoting resource efficiency. Jaw stone crushing equipment market size is poised to gain notable traction between 2023 and 2032 owing to their reliability, efficiency and versatility in various industries. Jaw crushing equipment are increasingly used in construction and other applications to offer ease of maintenance and cost effectiveness. Moreover, industry players are taking efforts towards business expansion for introducing innovative jaw-crushing equipment. For instance, in April 2023, Rubble Master launched a 44” * 28” jaw crusher to incorporate its new high efficiency drive concepts and innovative features.
According to Hailstone, India’s competitive stone crushing equipment industry sees equipment prices fluctuate based on quality, brand, and features. Maharashtra, Karnataka, and Tamil Nadu are key players, commanding the highest prices. The growing construction and mining industries have led to a surge in the number of crusher machine manufacturers in India, each offering unique crushers specializing in jaw or impact crushing. Cone crushers are ideal for secondary and tertiary crushing, while impact crushers excel with soft and medium-hard materials. The demand for impact crushers is driving manufacturers to produce superior-quality products and offer competitive prices.
The stone crushing industry is expected to undergo significant advancements in the near future due to increasing demand. Cone crusher manufacturers in India are at the forefront of this development, aiming to produce more efficient and eco-friendly machines. Technologies such as automation, AI, machine learning, and the use of modern materials can improve working conditions, results, and maintenance costs. The use of solar and wind power can also play a significant role in reducing carbon emissions and promoting sustainability. New stone-crushing technologies such as AI optimization, automation, and virtual reality training are emerging to enhance productivity, safety, and equipment availability.
The stone crusher machine price in India remains a significant consideration for buyers, and manufacturers must remain competitive by offering high-quality machines at reasonable prices. The industry is poised for a transformational period, with jaw crusher manufacturers and cone crusher specialists leading the way towards a more efficient, eco-friendly, and sustainable future.
Hailstone’s solutions include ‘Smart Impact Series’, vertical shaft impactor etc. Hailstone wheel mounted crusher plant is equiped with VSI EP7X187 crushing unit especially designed for crushing hard rocks such as granite and basalt. Its 650 tph, HTS 1860 4D, 4 deck track screen with deck size of 6000×1800 mm has dual power. Its HTC 270, track cone crushers come in capacities of 70 to 280 tph.
Other products include HW Series vertical shaft impactors, JC series jaw crushers, HF series cone crushers, EC series cone crushers, and in the washing line, the company produces AC series air classifiers, CF series Clarifiers, BCD and Duo series bucket wheel classifiers, and Adwash series of material washing solutions.

While there have been various enhancements and improvements taking place over the years, some of them have been captured above, let’s track few of the upcoming trends that will shape the future course of action in crushing & screening market…
Mobirex MR 130i Pro diesel-electric crusher by Kleemann GmbH was honoured German Design Award due to high functionality, performance and ergonomics. A Wirtgen Group brand, the consortium said the Kleemann plant “impressed the jury of the German Design Award with its combination of environmentally friendly drive concept, exemplary functionality and user-friendliness in interaction with a striking design.”
The modern impact crusher makes all-electric operation possible. At the same time, the design reflects the requirements of functionality, performance and ergonomics in an impressive manner. The newest Mobirex is the latest unit of the ‘pro’ line from Kleemann. The impact crusher is used as a primary and secondary crusher in soft to medium-hard natural stone and recycling. It’s engine uses a 550 kVA generator with a rated speed of 2,100 RPM and a power supply output between 641 to 2,100HP.
“Thanks to the diesel-electric drive – E-DRIVE – with the option of an external power supply, local emission-free operation is possible,” states the company. “A further positive feature of the plant is its high level of user-friendliness thanks to the intuitive digitized user guidance. A combination of smartphone, radio remote control or touch panel makes control from a distance possible.
The WRC 240(i) from Wirtgen expands the portfolio of wheeled soil stabilizers designed for processing of stony ground. This machine breaks coarse rocks in-situ, as found in hand-packed pavement layers (e.g. Telford bases) or stony soils and produces a homogeneous mix in a continuous process. A working width of 2,320 mm and a working depth of up to 510 mm enables an output of up to 600 tons per hour.
In addition to the crushing of rocks and stones with an edge length of up to 300 mm and strength up to 200 MPa, the machine can add cement and water in the same pass, for instance in the preparation of base layers. Here, the cement is pre-spread with a binding agent spreader and the water required is sprayed into the mixing chamber of the Rock Crusher via the machine’s Varioinjection bar. The machine can also be used for soil stabilization. For this application, pre-spread binding agents, such as lime or cement, are mixed into the existing soil with insufficient bearing capacity, which is then transformed in-situ into a high-grade construction material and deposited evenly behind the machine. The main task of the WRC is the granulation and mixing of a variety of soils, courses and layers to produce a homogeneous final product in a continuous process. As opposed to the removal and replacement of material, the processes help conserve resources and lower CO2 emissions.
Terex offers the capability of remote access to crushers, enabling the monitoring of alarms and trends. This functionality proves invaluable for troubleshooting, and in some instances, facilitates online monitoring and adjustments. This proactive approach ensures that crushers are operating at optimal conditions, with a focus on maximizing motor load and crushing pressures. The ability to remotely access and monitor equipment reflects Terex’s commitment to leveraging technology for efficient maintenance, timely intervention, and the sustained peak performance of crushers in diverse operational conditions.
Terex takes a comprehensive approach to crusher design, providing a variety of jaw and cone liner profiles across its entire range of cone and jaw crushers, maintaining a consistent global footprint. This commitment to diverse liner profiles ensures that Terex crushers can be tailored to specific needs and applications. Additionally, Terex has invested in advanced screen monitoring equipment. This equipment is designed to measure and record movements at all four points on the screen. This meticulous monitoring allows for a detailed analysis of screen behaviour, contributing to enhanced performance analysis and the optimisation of screening processes.
Terex WV2000LS combines the rugged reliability of our 2000SD Vertical Shaft Impact (VSI) crusher with our efficient and durable inclined screen. The result is a high production crushing and screening machine. The highly mobile Terex WV2000LS wheeled plant is suitable for working in many different crushing circuits and will handle almost any aggregate material. The WV2000LS is an all electric plant which easily ties into new or existing secondary, tertiary and quaternary crushing applications. The Terex WV2000LS is designed to help companies achieve greater profitability. The high performance four-deck screen and powerful VSI crusher have the flexibility to deliver four variously sized products with increased efficiency.
Metso is launching the XM Series, a highly advanced premium crushing solution that combines intelligence, durability and lifetime value with a new digital package, resilient engineering and unmatched warranties. The groundbreaking Metso XM Series crushing solution designed for demanding mining applications is built to take crushing performance beyond the conventional.
“What’s transformative in the XM Series package is that it combines and gives access to the latest in digital technologies, SmartCone, SmartStation and Mineral Crusher Pilot (MCP) automation. SmartCone, ideal for product size control, can increase production by up to 10%. MCP automation provides the easiest and fastest integration connectivity and allows for not just remote diagnostics, but remote actions, too. The three of these technologies combined give the edge needed to make smarter decisions about the crusher and prevent downtime,” explains Vinicius Vilela, Vice President, Mining Crushers at Metso.
“On top of this, as the first of its kind available in the mining industry, the warranty covers up to 25 years of life for the crusher, conditional on following specific terms and conditions,” notes Vilela. The XMTM series solution uses the robust and safe Nordberg® MP SeriesTM cone crushers and SuperiorTM MKIII primary gyratory crushers. The Xtreme forged head of the Nordberg® MP SeriesTM crushers are three times more robust than industry standards and are the most durable head designed for the most demanding crushing applications. Other notable upgrades for the MP XMTM series include top-mount clamping cylinders, hydraulic socket, accumulator monitoring system and tramp release half nut. The lifetime of the cavity liner can also be increased up to 50% and the protective parts’ lifetime four times. The lifetime of the SuperiorTM primary gyratory’s mantle shell is up to 50% longer and offers double the concave and protective parts lifetime. The option of Rotable top shell solution decreases downtime, improves safety and has sustainability advantages.
FLSmidth Vibrating Grizzly Feeders are designed to withstand the heavy duties typically present in primary applications. They can process run of mine material with up to 2m edge length with minimum downtime and thereby guarantee continuous operation. The company offers various types of Vibrating Grizzly Feeders, which can be equipped with grizzly bars or grizzly fingers for sticky and difficult-to-screen feed materials. The grizzly bars are made of highly wear resistant steel and offer maximum lifetime of the screen decks and can be arranged in single, double, triple and even quadruple stepped options subject to duty requirements. The Vibratory Feeder’s units are especially designed for harsh operations where lumps require separation from fine ore. The fine ore passes through the tapered grizzly fingers and bypassing the crusher, whereby the lumps are fed into the primary crusher. The process maximizes the overall crushing plant capacity and reduce the wear within the crusher.
Looking forward, IMARC Group expects the market to reach US$ 34.2 Billion by 2032, exhibiting a growth rate (CAGR) of 4.5% during 2024-2032. Increasing construction activities, rising investments in various infrastructure projects, and growing product usage in energy production represent some of the key factors driving the market.

  • Crushing, Screening, & Mineral Processing Equipment Market Size was valued at US$25.7 billion in 2023 and is expected to reach US$41.3 billion by the end of 2030 with a CAGR of 6.6% during the forecast period 2023-2030, according to Verified Market Reports.
  • Mobile crushers and screeners find extensive application in stone quarries due to their flexibility, efficiency, and ability to operate in varied environments.
  • According to Fact.MR report, the global screening equipment market has reached a valuation of US$6.78 billion and is anticipated to expand at a CAGR of 5.6% to reach 11.69 billion by the end of 2032.

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