Estimate crusher output quickly for any rock blend. Adjust belt, density, and operating factors easily. Plan shifts, trucks, and stockpiles with confident numbers today.
| Scenario | Area (m²) | Speed (m/s) | Density (t/m³) | Util (%) | Avail (%) | Adjusted (t/h) |
|---|---|---|---|---|---|---|
| Primary limestone, steady feed | 0.14 | 2.20 | 1.55 | 88 | 93 | ~1,496 |
| Hard basalt, higher moisture | 0.12 | 2.00 | 1.80 | 82 | 90 | ~932 |
| Recycled aggregate, higher fines | 0.10 | 1.80 | 1.45 | 85 | 92 | ~672 |
Theoretical throughput (t/h)
Qtheoretical = A × v × ρ × 3600
Adjusted throughput (t/h)
Qadjusted = Qtheoretical × U × Av × Fchoke × Fmaterial × Ffines × Fmoisture
Crusher throughput begins with conveyor flow: loaded area, belt speed, and bulk density define the theoretical tonnage rate. In reality, the crusher, feeder, transfer points, and screening can become the bottleneck. This calculator separates the physics-based estimate from operating conditions so you can quantify losses, compare shifts, and prioritize the changes that raise sustained production.
Bulk density changes with geology, gradation, and moisture. Limestone and crushed concrete often fall near 1.4–1.7 t/m³, while dense igneous rock may reach 1.9–2.1 t/m³. A conservative density reduces the risk of over-promising trucks and stockpiles. If you have belt scale or lab data, update the input to match the current blend.
Loaded cross-sectional area depends on belt width, troughing, and how steadily the feeder presents material. When area is unknown, estimating with width, load height, and a shape factor provides a practical planning value. Belt speed increases capacity linearly, but higher speeds can increase spillage and wear. Pair speed changes with stable feed control to avoid surges.
Utilization reflects how much of scheduled time is truly producing—idling, waiting, and short stops reduce it. Availability captures maintenance and breakdown impacts across the period. Keeping them separate helps target improvements: tighter shift routines raise utilization, while preventive maintenance increases availability. Together they often explain most of the gap between nameplate and achieved throughput.
High fines can reduce effective flow by increasing cohesion and buildup in chutes. Moisture raises the risk of bridging and carryback, especially above 8–12%. This calculator applies adjustable fines and moisture factors to reflect site conditions. Example data: Area 0.14 m², speed 2.20 m/s, density 1.55 t/m³, utilization 88%, availability 93% gives about 4,900 t/day at 10 hours.
It is the conveyor-based tonnage rate calculated from loaded area, belt speed, and bulk density, assuming continuous flow with no downtime or restrictions.
Utilization, availability, and correction factors account for stops, maintenance, inconsistent feed, material hardness, fines, and moisture. Small reductions across several factors compound quickly.
Use the belt width, average load height, and a shape factor. Start around 0.60 and adjust after comparing results to belt scale data or known production rates.
For many sites, 75–90% is typical depending on haul cycles and operational discipline. Use lower values for frequent relocations, changeovers, or variable feed conditions.
Reduce it for very hard, abrasive rock that limits crusher performance, and increase it slightly for easier material. Calibrate using historical plant data when available.
Moisture promotes buildup and bridging, reducing flow and increasing cleaning time. If you see carryback or chute plugging, apply a stronger moisture penalty and validate with shift logs.
Yes. Enter truck payload to estimate trucks per hour and minutes per truck. Use adjusted throughput for realistic dispatch spacing and queue management.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.