“Our limestone was clogging the crusher every shift — we lost 30% production time. It wasn’t the machine, it was the screen gap.”
—— Ahmed, Plant Manager, Saudi Arabia
When your ore has high moisture content — say, above 8% — traditional impact crushers start acting up. You’ll see frequent blockages, uneven discharge, and faster wear on the liner and hammer. But here's what most operators miss: the solution often lies in one simple adjustment — screen gap setting.
Studies show that when wet material (like clay-rich limestone or basalt from tropical regions) enters a crusher at a moisture level of 6–12%, the effective particle size drops by 15–25%. This leads to:
If you’re running a 50 tph system and lose 25% due to poor screening, that’s not just downtime — it’s real money gone.
| Ore Type | Moisture Range (%) | Recommended Screen Gap (mm) |
|---|---|---|
| Limestone (crushed) | 6–10% | 15–20 mm |
| Granite / Basalt | 8–12% | 20–25 mm |
| Chert / Sandstone | 10–15% | 25–30 mm |
These aren't arbitrary numbers — they’re based on field tests conducted across 37 mines in Southeast Asia and Africa. The key is balancing fine product control with flow stability.
Pro tip: Use a handheld moisture meter — it’s cheaper than losing 15% capacity per month.
In a case study from a quarry in Indonesia, adjusting from 12 mm to 22 mm screen gap reduced clogging incidents by 78% and boosted daily output from 42 tons to 58 tons — all without changing the machine.
What’s your mine’s average moisture level? Share it below — we’ll help you find the right gap setting.
See How Our CI5X Crusher Adapts Automatically to Wet Ore Conditions
Facebook