6 key advantages of high-performance cone crushers for higher output and lower costs

Modern cone crushers, equipped with the latest technological advancements, are built to do just that. Metso's Nordberg® HPe Series™ cone crushers enhance performance, safety, and efficiency. Built on the strengths of earlier models, the HPe Series introduces innovative technologies that add more value for customers. Whether used for secondary, tertiary, or quaternary crushing, these crushers boost output but also minimize risks and operational costs. Let’s explore the key features of this advanced cone crusher technology and their impact on your bottom line.

1. Crush more with enhanced kinematics and optimized chamber geometry

The HPe Series is designed for maximum output. The HP200e and HP350e models, for example, deliver up to 20% and 10% more production, respectively​. This is achieved through increased motor power and head motion and more efficient chamber designs. These improvements translate directly into increased profitability. For instance, in secondary application using the HP200e could generate an added 60 000 tons per year, while in tertiary applications can add 45 000 tons per year​.

This boost in performance ensures that your operation can handle increased demand without needing added equipment or personnel, making it an easy decision for any high-capacity crushing operation.

2. Optimize product yield with narrow fraction cavity

Another standout feature of the HPe Series is the introduction of narrow fraction (NF) cavities, specifically designed for tertiary and quaternary crushing. These narrow fraction cavities optimize the product grading curve, reducing the production of unwanted fines such as sand, when it's not the wanted end product.

. By improving the yield of valuable aggregate fractions like 5-11 mm (or 3/8 x 3/16 in) by 5 percentage points, you could see up to 20% less sand production. For an HP200e crusher, that’s 12 metric tons per hour of more sellable product, translating to an added 24 000 tons per year​. For any operation looking to minimize waste and maximize the value of each ton processed, NF cavities provide a strategic advantage that significantly improves profitability.

3. Avoid downtime by preventing ring bounce 

Ring bounce, caused by exceeding maximum crushing force, can be a significant issue in crushing operations, leading to mechanical damage and inefficiencies. The HPe Series features an optional advanced ring bounce monitoring system that alerts operators in case maximum crushing force is exceeded. By preventing ring bounce, you not only protect the crusher but also keep consistent output and reduce the risk of costly downtime.

Ring bounce monitoring feature allows getting higher yield of wanted end products safely without overloading the crusher while minimizing production of oversized material getting into recirculation. Assuming 10% higher yield of product and less oversized material, the impact would be around 30,000 tons/year.

4. Extend liner life and cut costs with the anti-spin brake

The HPe Series comes equipped with an innovative head anti-spin brake, which extends the life of liners by reducing the wear and tear caused by first rocks entering the cavity. Less wear development as the head is spinning less. This feature enhances operational efficiency and reduces liner replacement costs by 5-10%, depending on how irregular the feed is. By slowing down the head spin while idling, the brake reduces the need of energy absorption as the first rocks enter the crusher, ensuring smooth operation and prolonging part life. Over a four-year period, this feature can reduce number of liner set changes by up to 10%, making a noticeable difference in both cost savings and operational uptime​.

5. Save time and money with fast liner changes using no-backing technology

Time is money, and nowhere is this more evident than during liner changes. Traditional cone crusher wear parts with backing materials can take up to two working days to replace. The HPe Series eliminates the need for backing materials, cutting the time required for liner changes to just one working day. This saves eight hours per change, adding up to 32 hours per year of extra production time with four liner changes per year. The no-backing liners also provide sustainability benefits by eliminating harmful chemicals and simplifying logistics, also contributing to operational efficiency.

6. Improve safety and ergonomics of your team with the new lifting tool

Safety and operational efficiency go hand in hand. The new feed cone lifting tool for the HPe Series is a game-changer, designed for easier and safer cone handling. Any heavy lifting, even if doable manually, may cause incidents and injuries if not done correctly and considering ergonomics. Now, with this mechanical lifting tool, incidents can be significantly reduced, protecting your personnel and equipment.

For example, the HP200e’s feed cone weighs 12 kg, and the HP350e’s feed cone weighs 18 kg. In the worst case, manually mishandling these can lead to injuries​. With this simple yet effective tool, those risks are minimized, saving both downtime and potential medical costs.

Latest crushing technologies drive maximum productivity

Finding ways to improve productivity and reduce costs in your aggregates process is a practical and smart approach. Metso's Nordberg® HPe Series™ cone crushers are designed to help operators meet these challenges head-on. With advanced technologies that enhance output, minimize downtime, and increase equipment lifespan, these crushers provide tangible benefits that impact your bottom line.

By integrating innovative features like the head anti-spin brake, no-backing liners, and ring bounce monitoring, you’re not only protecting your equipment but also ensuring safer, more efficient operations. Choosing the HPe Series isn’t just about investing in a crusher - it’s about investing in the future success of your business.

Metso launched its first Nordberg® HPe Series™ cone crusher in 2023, currently offering two models: HP200e and HP350e. Introduction of the next models is progressing, and they will become available shortly. Stay tuned for the next releases.

Disclaimer: In all of the above calculations we have used production rate of 150 tons per hour for HP200e and 200 tons per hour for HP350e. The used tons are in metrics tons. The performance figures and cost savings mentioned in this blog are indicative and based on typical operational scenarios. The numbers are intended as guidance only and are not guaranteed. Actual results may vary depending on specific application conditions. For precise information and tailored advice, please consult your nearest Metso distributor or a certified Metso expert.