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Investing in the Next Generation

������ý is Mellott’s pre-apprentice training program designed to provide local students with hands-on experience and real-world exposure across multiple areas of the company. Through classroom instruction, and on-the-job learning, students gain valuable industry knowledge while also earning college credits through Blue Ridge Community and Technical College.

The Class of 2026 also marked an important milestone for the program as ������ý’s first co-ed class. Throughout the year, students worked alongside Mellott team members and subject matter experts to develop practical skills, explore different departments, and gain experience in a professional environment.

A Year of Growth and Achievement

Throughout the program, students participated in hands-on training and learned directly from experienced professionals across the company. The goal of ������ý is not only to educate students about the industry, but also to help prepare them for long-term careers and future success.

Dave, Mellott’s Technical Trainer, reflected on the accomplishments of this year’s graduating class and the impact the program continues to make.

“It has been an exciting year teaching the material through our new LMS (Learning Management System) to our first co-ed class. I am proud of the hard work, growth, and dedication each student has shown throughout this program. Seeing every student graduate and accept full-time offers in different departments within our company is a true reflection of their commitment and potential.

As their instructor, it has been an honor to be part of the beginning of their journey with Mellott. I am excited for the next generation of leaders, skilled workers, and team members they are becoming. Congratulations, and I look forward to seeing the great things you will accomplish.”

Looking Ahead

One of the most exciting outcomes from this year’s program is that each graduate has accepted a full-time position within different departments across Mellott. Their transition from students to full-time team members reflects both their dedication and the success of the ������ý program.

������ý continues to demonstrate the company’s commitment to workforce development, hands-on education, and investing in the future of the industry. By giving students opportunities to learn directly from experienced professionals, the program helps build strong foundations for the next generation of leaders and skilled workers.

Congratulations again to Bray, Bryson, Ashlyn, Hope, and Sydney on this outstanding achievement. We look forward to seeing all you accomplish in the years ahead!

The post ������ý Celebrates the Graduation of the Class of 2026 appeared first on Mellott.

Here are three of the most common mistakes that may be killing your crusher liners faster than necessary.

1. Running the Crusher Too Empty

A common misconception is that a lightly loaded crusher reduces wear. In reality, operating a cone crusher with too little feed can dramatically accelerate liner wear and create uneven wear patterns.

When the crushing chamber is not kept full:

• Material flow becomes inconsistent
• Liners experience concentrated wear in specific areas
• The crusher may bounce or experience unstable crushing forces
• Production efficiency drops

helps distribute crushing forces evenly across the liners, maximizing wear life while maintaining a consistent product shape and throughput.

Warning Signs

• Uneven liner wear
• Reduced throughput
• Fluctuating power draw
• Poor product gradation

Best Practice

Maintain a consistent feed rate and proper chamber level whenever possible. Automated feed control systems can help stabilize operation and extend liner life.

2. Incorrect Feed Distribution

Even with a full chamber, poor feed distribution can quickly destroy liners.

If material is feeding heavily to one side of the chamber:

• One side of the liner wears faster
• Production becomes less efficient
• The crusher may experience imbalance and unnecessary stress
• Liner utilization drops significantly

This issue is especially common when transfer points, conveyors, or feeders are not centered correctly.

Warning Signs

• One-sided liner wear
• Uneven manganese thickness during inspections
• Poor product consistency
• Increased recirculating load

Best Practice

Inspect feed alignment regularly and ensure material is centered into the crushing chamber. Feed distribution should remain consistent across the full width of the chamber to maximize liner utilization.

3. Waiting Too Long to Replace Liners

Running liners past their optimal wear point may seem like a cost-saving move, but it often creates the opposite effect.

Worn liners can:

• Reduce crushing efficiency
• Increase power consumption
• Produce inconsistent product
• Create excessive stress on crusher components
• Increase the risk of mechanical failure

As liners wear, chamber geometry changes. Once the profile is no longer performing efficiently, production losses can outweigh any remaining liner value.

Warning Signs

• Sudden drop in production
• Higher recirculating loads
• Increased power draw
• Poor product shape
• More frequent operational adjustments

Best Practice

Monitor liner wear consistently and replace liners before performance begins to decline significantly. Tracking wear life and production trends can help identify the ideal replacement window.

The Bottom Line

Crusher liners are designed to wear — but premature wear is often preventable. Proper feeding practices, consistent chamber loading, and proactive maintenance can dramatically improve liner life while reducing downtime and operating costs.

Small operational adjustments can have a major impact on:

• Wear life
• Production efficiency
• Equipment reliability
• Overall cost per ton

When liner performance improves, your entire operation benefits.

Need help optimizing your crushing operation or selecting the right wear parts? The team at Mellott can help evaluate your application, operating conditions, and wear patterns to maximize performance and liner life.

The post 3 Mistakes That Are Wearing Out Your Crusher Liners Faster appeared first on Mellott.

At Mellott, we maintain a deep inventory of high-demand crusher parts so you can get what you need—fast—without waiting on long lead times or risking extended shutdowns.

Why In-Stock Spare Parts Are Critical for Crusher Uptime

Crushers operate in demanding environments where wear is inevitable. From liners and mantles to bearings, bushings, and hydraulic components, parts will eventually need replacement. The question isn’t if—i��’s when.

Keeping essential parts readily available helps you:

• Reduce unplanned downtime
• Avoid costly emergency shipping delays
• Maintain consistent production output
• Extend equipment life with timely replacements

When parts are on the shelf, your operation stays in control.

What Crusher Spare Parts Mellott Keeps in Stock

Mellott’s inventory is built around the real-world needs of aggregate producers. We stock a wide range of ��and compatible crusher components, spare parts and including:

• Cone crusher mantles and bowl liners
• Jaw dies and cheek plates
• Main shafts and head assemblies
• Eccentric bushings and countershafts
• Hydraulic cylinders and seals
• Wear components for daily maintenance

Our goal is simple: get you the right part, right when you need it.

Faster Turnaround = Lower Cost of Downtime

Waiting weeks for a part shipment can turn a small mechanical issue into a major production setback. With in-stock availability, Mellott helps reduce your total cost of ownership by minimizing idle time and emergency repair scenarios.

In many cases, having the right spare part on hand can mean the difference between a same-day fix and a multi-day shutdown.

More Than Parts: Full Support From Crusher Experts

When you source spare parts from Mellott, you’re not just buying inventory—you’re tapping into decades of crushing and screening expertise. Our team helps ensure:

• Proper part fit and compatibility
• Guidance on wear life and replacement timing
• Recommendations to improve performance and reduce future failures

We support your equipment from installation through its full lifecycle.

Get the Parts You Need—When You Need Them

If you’re serious about minimizing downtime and maximizing productivity, having a reliable source for is essential.

Explore Mellott’s inventory and keep your operation moving without interruption.

Contact Mellott today to check availability or request a quote.

The post Keeping Your Operation Running: Why In-Stock Spare Crusher Parts Matter appeared first on Mellott.

At Mellott, we understand that keeping your operation running is critical. Below are key maintenance practices for crushers, screens, and conveyors that can help extend equipment life and maintain peak performance.

Why Preventive Maintenance Matters for Rock Crushing Equipment

Preventive maintenance is essential for any crushing operation. Routine inspections and scheduled service can help identify worn components before they fail, allowing you to plan repairs instead of reacting to unexpected breakdowns.

Benefits of regular maintenance include:

• Improved production efficiency
• Reduced unplanned downtime
• Lower repair costs over time
• Extended equipment lifespan
• Safer operating conditions

When equipment is maintained properly, it performs more consistently and delivers better results.

Crusher Maintenance: Protecting Wear Parts and Performance

Rock crushers use compression or impact forces to break down material. Because of this demanding process, wear liners and other internal components take significant abuse.

Monitor Manganese Liners

Many crushing chambers use manganese liners because manganese hardens when impacted, making it ideal for high-wear applications. Even with this durability, liners eventually wear down and must be replaced.

Waiting too long to change liners can reduce production and increase operating costs. Many operations monitor throughput closely and schedule liner replacement when production begins to noticeably decline.

Inspect Other Critical Wear Components

In addition to liners, operators should routinely inspect:

• Wear plates
• Blow bars
• Shoes and anvils
• Bearings and shafts

Replacing worn parts early can prevent more serious mechanical issues later.

Maintain Lubrication Systems

Proper lubrication is vital to crusher performance. Bearings, shafts, and other moving components should be greased and serviced according to manufacturer recommendations. Oil levels and filters should also be checked regularly.

Screening Equipment Maintenance Tips

Screening equipment is a crucial part of aggregate processing because it separates material by size. Due to constant vibration, screens require consistent maintenance to remain balanced and efficient.

Replace Worn Screen Media

Screen media wears over time, whether it is wire cloth, rubber, or urethane. Running damaged media too long can lead to reduced efficiency and possible damage to supporting components.

To maximize service life:

• Keep screen media properly tensioned
• Ensure correct support across the deck
• Replace media on a planned schedule

Keep Components Clean and Serviced

and material buildup can impact springs, motor bases, and lubrication systems. Regular cleaning and oil changes help maintain reliable screen performance.

Conveyor Maintenance for Crushing Systems

Conveyors are the link between each stage of the crushing process. If conveyors stop, production stops.

Inspect Belts and Rollers

Routine inspections should focus on:

• Belt condition and tracking
• Roller wear or seizure
• Material buildup
• Misalignment

Belts often last longer with proper cleaning and repair, but damaged sections should be addressed quickly to avoid additional issues.

Keep Belts Clean

Material carryback can create excessive wear and housekeeping challenges. Many operations use belt scrapers or cleaning assemblies to keep belts clear and efficient.

Lubricate Moving Components

Rollers and bearings should be cleaned and lubricated regularly to prevent premature wear caused by dust and debris.

Build a Reliable Aggregate Equipment Maintenance Program

A strong maintenance program includes more than occasional repairs. The most successful operations focus on:

• Daily walk-around inspections
• Scheduled wear part replacement
• Proper lubrication intervals
• Clean equipment and work areas
• Accurate service records
• Planned shutdown maintenance

This proactive approach helps minimize downtime while maximizing output.

Trust Mellott for Rock Crusher Equipment Service and Support

When your operation depends on reliable crushing equipment, expert support matters. Mellott provides maintenance services, repairs, rebuilds, and aftermarket support designed to keep your plant running at its best.

Whether you need scheduled service, emergency repairs, or replacement parts, our team has the experience to help you improve equipment performance and extend the life of your investment. Contact Mellott today to learn more.

The post Rock Crusher Equipment Maintenance: Best Practices to Maximize Uptime and Performance appeared first on Mellott.

A Real-World Look at Manufacturing Careers

Throughout the day, students toured Mellott’s facilities, gaining exposure to multiple departments including:

• Manufacturing and fabrication
• Equipment service and maintenance
• Engineering and design
• Sales and operations

Mellott team members shared their career paths and day-to-day responsibilities, helping students better understand the variety of roles available in the aggregate and construction industries.

Inside the Mellott Facility: A Guided Tour Experience

Students participated in a comprehensive facility tour where they were able to see each area of Mellott’s operations up close. As they moved through the shop, offices, and workspaces, they interacted directly with Mellott team members who explained their roles, daily responsibilities, and the processes that keep the company running.

This experience gave students a clearer understanding of how different departments work together and allowed them to ask questions in real time—making the visit both engaging and informative.

Mock Interviews Provide Real-World Experience

Students also participated in mock as part of the visit. Prior to the event, they submitted job applications and resumes, then sat down with Mellott team members for one-on-one interviews.

For many students, this was their first interview experience. The exercise provided a practical, low-pressure environment to build confidence, practice communication skills, and receive valuable feedback.

By simulating real hiring scenarios, students were able to strengthen interviewing skills they can carry with them into future job opportunities, internships, and career paths.

Building the Future Workforce

The event also reinforced Mellott’s core values of safety, integrity, commitment, respect, and excellence. Throughout the day, students saw firsthand how these principles guide daily operations—from prioritizing safe work practices to fostering a culture of accountability and teamwork.

By connecting these values to real-world experiences, students gained a better understanding of what it takes to succeed in a professional environment. Mellott remains committed to investing in workforce development and creating awareness around high-demand careers in manufacturing and the trades, while shaping future professionals who embody these same values.

Strengthening Community Partnerships

Mellott’s partnership with reflects an ongoing commitment to community engagement and education. Events like this help students make informed decisions about their future—whether that includes college, trade school, or entering the workforce directly.

As the Class of 2026 prepares for graduation, Mellott is proud to support the next generation of skilled professionals and looks forward to continuing these impactful experiences.

The post Mellott Hosts Southern Fulton Class of 2026 for Hands-On Career Exploration appeared first on Mellott.

At Mellott, we’ve worked with operations of all sizes—and one thing is clear: understanding your crusher wear parts is one of the fastest ways to improve efficiency and profitability.

What Are Crusher Parts? (And Why They Matter)

Crusher parts fall into two main categories:

• – Components that naturally wear down over time
  (jaw plates, mantles, concaves, blow bars, liners)
• – Mechanical components that may need replacement
  (bearings, shafts, toggles, hydraulic parts)

Wear parts directly impact:

• Production output
• Material gradation
• Cost per ton

If they’re worn or poorly matched to your application, your entire operation suffers.

The Most Common Crusher Wear Parts (And Their Roles)

• Jaw plates: Primary crushing surface
• Cheek plates: Protect the crusher frame

Worn jaw plates reduce crushing efficiency and increase strain on the machine.

• Mantle: Moves to crush material
• Concave: Stationary surface for compression

These determine final product size and consistency.

• Blow bars: Strike material at high speed
• Impact plates / liners: Control material flow and protect the housing

Material type (concrete vs limestone vs asphalt) drastically affects wear life.

5 Signs ����’s Time to Replace Your Crusher Parts

1. Drop in production output
2. Inconsistent material size
3. Increased recirculation load
4. Visible wear or cracking
5. Rising cost per ton

Ignoring these signs leads to bigger failures—and more expensive repairs.

How to Extend the Life of Your Crusher Parts

Smart operations don’t just replace parts—they maximize them.

Here’s how:

• Match the part material to your application (manganese, chrome, etc.)
• Maintain proper feed size and consistency
• Avoid overloading the crusher
• Perform routine inspections
• Rotate wear parts when possible

At Mellott, we help customers dial in these factors to get the most out of every part.

OEM vs Aftermarket Crusher Parts: What’s Right for You?

This is one of the most common questions operators face.

OEM parts

• Designed specifically for your machine
• Consistent quality and fit
• Typically higher upfront cost

Aftermarket parts

• More cost-effective options
• Can perform equally well when properly engineered
• Greater flexibility depending on supplier

The key isn’t just OEM vs aftermarket—i��’s working with a supplier who understands your operation.

Why the Right Supplier Matters

Not all crusher parts are created equal—and neither are suppliers.

The right partner will:

• Help you choose the correct parts for your material and machine
• Reduce downtime with fast availability
• Provide technical expertise, not just sell parts

That’s where Mellott stands apart. We don’t just supply parts—we help optimize your entire operation.

Final Thoughts: Reduce Downtime, Increase Profit

Crusher parts aren’t just a maintenance item—they’re a major lever for profitability.

By choosing the right parts, replacing them at the right time, and working with a knowledgeable partner, you can:

• Increase uptime
• Improve product quality
• Lower your cost per ton

If you’re looking to get more out of your equipment, the conversation starts with your parts strategy.

Need Help Choosing the Right Crusher Parts?

The team at Mellott can help you find the best solution for your operation—whether you’re focused on performance, cost savings, or both.�� Call 800.634.5634 or contact us HERE.

The post The Complete Guide to Crusher Parts: How to Maximize Uptime and Reduce Cost Per Ton appeared first on Mellott.

That is why more contractors are turning to mobile crushing equipment. Instead of hauling blasted rock, concrete, asphalt, or demolition material to a stationary plant, track-mounted crushers and screens allow you to bring the plant directly to the material.

Mobile crushing equipment reduces hauling costs, lowers cost per ton, speeds up project completion, and .

Why Hauling Costs Hurt Contractor Profitability

On many contractor jobs, material is excavated or blasted and then loaded into haul trucks to be transported to a stationary crushing plant. After processing, the finished material may then need to be hauled back across the site for stockpiling or use.

This creates multiple layers of unnecessary cost, including:

• Fuel for haul trucks and loaders
• Labor for truck drivers and operators
• Increased wear on tires, brakes, and drivetrains
• More machine hours on support equipment
• Added maintenance costs
• Delays from traffic flow and bottlenecks on the jobsite
• More dust, noise, and congestion

The larger the site, the more expensive these hauling costs become. On quarry, roadbuilding, demolition, and site development jobs, contractors can spend significant amounts of money just moving material from one location to another instead of processing it.

Bring the Crusher to the Rock

One of the biggest advantages of mobile crushing equipment is the ability to position the crusher directly at the face, blast site, or demolition area.

Track-mounted plants can move around the site as the job progresses. Instead of hauling raw material long distances, contractors can use excavators or wheel loaders to feed the crusher directly.

This dramatically reduces truck traffic, eliminates double handling, and lowers fuel consumption. In many applications, haul trucks can be eliminated entirely.

Mobile crushers are especially effective for:

• Quarry face crushing
• Road construction projects
• Concrete and asphalt recycling
• Site development
• Utility projects
• Demolition jobs
• Temporary aggregate production

Modern mobile crushers can also be paired with mobile screens and conveyors to create a complete portable crushing train that can move with the project.

�ѱ�ٲ���’s mobile crushers are designed to reduce hauling by allowing operators to bring crushing equipment directly to the material rather than transporting the material to a fixed plant.

Lower Cost Per Ton

Reducing haul distances has a direct impact on cost per ton.

When contractors eliminate unnecessary truck movements, they can lower:

• Fuel costs
• Labor costs
• Machine wear
• Maintenance expenses
• Downtime
• Material handling costs

That means more tons produced with fewer resources.

For contractors bidding work, this can create a major competitive advantage. Lower operating costs make it easier to stay profitable while remaining aggressive on pricing.

Track-mounted crushers also help maximize production because they spend less time waiting on haul trucks and loaders. Material can be processed faster and more consistently, helping crews stay on schedule.

Mobile crushing plants are widely used because they reduce the need for hauling, cut operational costs, and improve productivity on both aggregate and recycling jobs.

Mobile Equipment Improves Jobsite Flexibility

Another key benefit of mobile crushing equipment is flexibility.

Contractor jobs are constantly changing. One week, the crushing plant may be processing shot rock at a quarry face. The next week, it may be crushing recycled concrete on a demolition site.

Track-mounted equipment can move quickly between locations and be repositioned as the project changes. Many mobile plants can be transported easily on a lowboy trailer and set up quickly once they arrive on site.

This allows contractors to:

• Move equipment between multiple jobs
• Start crushing faster
• Follow the material as excavation progresses
• Reduce setup and teardown time
• Avoid building permanent infrastructure

�ѱ�ٲ���’s and equipment is designed for quick relocation, flexible positioning, and integration with screens and conveyors to create a complete mobile crushing spread.

Mobile Crushing Helps Reduce Fuel Use and Emissions

Fewer haul trucks on-site also means lower fuel consumption and reduced emissions.

By crushing directly at the source, contractors can significantly cut the number of truck trips needed to move raw material around the site. This reduces diesel usage, lowers operating costs, and supports cleaner jobsite operations.

Some mobile crushing equipment also offers hybrid or electric drive options, which can further reduce fuel consumption.

�ѱ�ٲ���’s hybrid mobile crushers use electric-driven systems that reduce fuel use and CO2 emissions compared to traditional diesel-hydraulic systems.

Improve Uptime with Smart Technology

Today’s mobile crushing equipment does more than just reduce hauling costs.

Modern crushers include , diagnostics, remote monitoring, and predictive maintenance tools that help contractors maximize uptime and avoid unexpected breakdowns.

Features like one-button start, remote controls, real-time performance monitoring, and adaptive feed control make it easier to keep the plant running efficiently.

includes predictive maintenance, remote monitoring, and production performance tools designed to improve uptime, increase throughput, and reduce fuel consumption. Field results show that adaptive feed control can improve throughput by 5–15% depending on the application.

The Bottom Line

For contractors, hauling material is expensive. The farther material has to travel, the more it costs in fuel, labor, maintenance, and lost productivity.

Mobile crushing equipment helps solve that problem by bringing the crusher directly to the rock, recycled concrete, asphalt, or demolition debris. Contractors can reduce hauling costs, lower cost per ton, improve production, and complete jobs faster.

Whether you are running a quarry, recycling yard, roadbuilding project, or temporary crushing spread, mobile crushing and screening equipment can help make your operation more efficient and more profitable.

To learn more about the right mobile crushing setup for your operation, Mellott can help evaluate your application and recommend the best combination of Metso LT and ST equipment.

The post How Mobile Crushing Equipment Reduces Hauling Costs on Contractor Jobs appeared first on Mellott.

are designed to deliver consistent performance across a wide range of applications. Whether you are producing base material, asphalt aggregate, manufactured sand, or concrete stone, the GP Series offers the flexibility and reliability needed to keep your operation running efficiently.

Excellent Versatility

One of the biggest advantages of the Metso GP Series is its ability to handle a wide range of applications and feed materials. GP cone crushers can be used in secondary, tertiary, and quaternary crushing stages, making them a flexible option for many different plant configurations.

Their adjustable stroke and multiple cavity options allow producers to fine-tune performance based on the desired product size and production goals. This flexibility helps operators achieve the right balance between capacity, reduction, and product shape.

Consistent Product Shape

Producing a high-quality end product is critical for many operations, especially when supplying asphalt, concrete, and road base materials. Metso GP Series crushers are known for delivering a consistent, cubical product shape.

A well-shaped product can improve downstream screening efficiency, reduce recirculating loads, and help producers meet demanding specifications for finished materials.

Efficient Performance and Lower Operating Costs

is designed for efficient crushing action, helping producers maximize throughput while controlling energy consumption. Their robust design and optimized crushing chamber geometry allow operators to process material effectively without unnecessary wear.

Because of their efficient design, GP cone crushers can often reduce operating costs through:

• Lower energy consumption
• Reduced liner wear
• Improved throughput
• Less downtime for maintenance
• Better overall plant efficiency

These savings can make a significant difference over the life of the machine.

Easy Maintenance

Maintenance is a major factor in keeping a crushing operation productive. Metso GP Series cone crushers are designed with serviceability in mind, offering features that make maintenance safer and easier.

Simple access to components, fewer service points, and durable wear parts help reduce downtime and make routine maintenance more manageable for operators and maintenance teams.

Reliable in Tough Conditions

Aggregate and mining operations demand equipment that can perform day after day in harsh environments. Metso GP Series cone crushers are built with durability and reliability in mind, allowing producers to confidently operate in demanding conditions.

Their proven track record across a variety of applications makes them a trusted choice for producers looking for dependable performance and long-term value.

Is a Metso GP Series Cone Crusher Right for Your Operation?

If your operation needs a versatile cone crusher that offers consistent product shape, reliable performance, and lower operating costs, the Metso GP Series may be the right solution.

At Mellott, we help customers evaluate their crushing needs and determine which cone crusher best fits their operation. Whether you need a secondary crusher, a tertiary crusher, or a complete plant design, our team can help you find the right solution.�� Reach out to us at 800.634.5634 or visit us HERE!

The post 5 Benefits of Choosing a Metso GP Series Cone Crusher appeared first on Mellott.

Their secondary plant features three crushers—HP500 STD, HP500 SH, and HP300 SH with various liners tailored to different product sizes, supported by three screens handling scalping and finishing.

Crushing Challenges & Material Insights

Konrad Diehl, Operations Manager at County Line Stone, shares,

“We are permitted to crush limestone from the Onondaga formation, with an average chert content of about 25%. Moisture coming out of the quarry is usually less than 2%. Our surge material fed into the HP500 STD with the is typically 2.5”–12”.”

The HP500 STD with the MX liner is the first crusher on the secondary plant and handles the most crushing, processing 600–700 TPH. Before switching to MX liners, the plant used 18% manganese aftermarket liners, which typically lasted 135,000–170,000 tons depending on chert content.

Konrad explains the challenge:

“Each liner has a substantial break-in period. Because we feed oversized material, sometimes 15”+, into the HP500, our break-in period is longer than usual. During the first week, throughput can drop about 20%, and only about 60% of the liner life is spent in prime crushing conditions. We mitigate this by sending larger material to surge during break-in and end-of-life periods.”

Even with planned preventative maintenance and efficient changeouts (5–6 hours per liner), the break-in period of traditional liners created temporary throughput reductions that impacted overall plant efficiency.

Why Switch to MX Liners?

County Line Stone decided to explore MX liners for several reasons:

• Longer wear life – Increasing prime crushing time from 60% to 80% of liner life.
• Reduced downtime – Fewer liner changes mean maintenance crews can focus on other plant areas.
• Increased throughput – More consistent TPH over the liner’s lifespan.
• Lower cost per ton – Improved efficiency spreads costs over more production.

Konrad notes:

“We heard MX liners could handle our larger material more efficiently and reduce the disruptive break-in periods. Price was our only hesitation, but we wanted to see if the investment would pay off.”

Real-World Results

Using data collected from calibrated belt scales and automation systems, County Line Stone tracked liner performance meticulously. For their aftermarket STD liners:

• Average crushing days: 26.7
• Average tonnage: 147,000 per liner
• Average TPH: 616
• Cost per ton for liner wear: $0.13

When they installed the MX liner, results were remarkable:

• Crushing days: 43
• Tonnage: 262,557 (77% increase)
• Crushing hours: 409
• Average TPH: 641 (increase of 25 TPH)
• Tons per adjustment: 284 (up from 189)

“The biggest improvement was the increase in tons processed per liner and tons per adjustment,” Konrad says. “Our traditional liners averaged 147,000 tons; the MX liner processed 262,000 tons. We also had fewer adjustments per hour, which improved crusher stability and overall plant efficiency.”

Additionally, consistent gradation increased from about 60% of liner life in prime form to 80% with MX liners. Automation now allows quick adjustments in two minutes for all three crushers, improving efficiency further.

��Safety & Maintenance Benefits

Beyond efficiency and throughput, MX liners also reduce maintenance exposure:

“Fewer liner changeouts mean less crane work, less prep time, and reduced risk for our team. Safety improves while plant uptime increases,” Konrad explains.

Cost Analysis

Looking at liner costs for the HP500 STD:

• Traditional aftermarket liners: $18,500/set × 7 changes/year → $168,140 total seasonal cost (~$0.17/ton including labor)
• MX liners (with tariff): $37,361/set × 4 changes/year → $171,524 total seasonal cost (~$0.17/ton)
• MX liners (without tariff): $29,889/set × 4 changes/year → $141,636 total seasonal cost (~$0.14/ton)

“With the MX liner, we also increased average TPH from 616 to 641, which spreads operating costs over more tons and further reduces cost per ton across the plant,” Konrad adds.

Looking Ahead

County Line Stone plans to continue running MX liners on the HP500 STD and is exploring MX options for other crushers, including a new C-150 jaw crusher coming in 2027.

“The MX liner has been a positive improvement. Higher throughput, longer wear life, and reduced maintenance requirements have made it a win for our operation. We plan to expand its use to other crushers as opportunities arise,” says Konrad.

County Line Stone’s experience demonstrates that investing in advanced liner technology, like MX liners, can lead to significant improvements in throughput, safety, and cost per ton, providing a measurable advantage for modern limestone operations.

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