Common Issues and Solutions in Limestone Sand Production Lines: From Jaw Crusher Selection to Screening Efficiency Optimization

Why Your Limestone Crushing Line Isn’t Performing as Expected — And How to Fix It Fast

Are you struggling with low throughput, frequent blockages, or inconsistent sand quality in your limestone crushing operation? You're not alone. According to a 2023 industry survey by the Mineral Processing Association, over 62% of small-to-mid-sized aggregates producers report suboptimal performance from their primary and secondary crushers — often due to poor equipment selection or misaligned process parameters.

The Hidden Link Between Jaw Crusher Design & Screen Efficiency

In a typical limestone processing line, the jaw crusher isn't just the first step — it's the foundation. A poorly designed chamber can cause downstream bottlenecks, even if your screen is top-tier. For example, when feed material has high clay content (like some limestone deposits), a traditional straight-line jaw cavity causes premature wear and uneven particle size distribution, leading to screen blinding — a common issue that reduces capacity by up to 30%.

That’s where the PEW Jaw Crusher from Zhengzhou Mining Machinery comes in. With its patented “V-shaped” crushing chamber, this machine delivers:

• Up to 25% higher output per hour vs. standard models
• 15–20% lower energy consumption per ton processed
• Reduced maintenance downtime — 40% fewer liner replacements annually

Real-World Case: From 70 t/h to 95 t/h in Just One Month

A quarry in Rajasthan, India, was stuck at 70 tons per hour using an older PE jaw crusher. After switching to the PEW model with optimized settings for their specific limestone hardness (Mohs scale ~3.5), they saw immediate improvements:

This wasn’t magic — it was smart engineering. The V-shaped chamber ensures uniform crushing force, minimizing fines generation and maximizing screen efficiency. And because the PEW uses less power while producing more consistent output, operators see real ROI within 6–9 months.

Whether you’re upgrading an existing plant or building a new one, choosing the right jaw crusher isn’t just about specs — it’s about understanding how each component works together. Don’t let outdated tech hold back your production goals.