Consider Metso upgrades to future proof your operations

The original article was published on Aggregates Business online magazine in September 2025.

In aggregates production, shifting market demands and evolving site conditions often require producers to rethink how they achieve performance, safety, and sustainability goals. Metso’s HP series crushers have long been a cornerstone of efficient crushing operations, but when targets rise significantly or regulations tighten, producers face a choice between optimizing their existing crushing circuit or possibly investing in new machines. These two options need to be considered, but optimization can bring improvements, but eventually reaches a ceiling. New machines may bring higher production and new technology, but can require considerable investment.

However, a third option producers should explore is to consider the growing range of upgrade options available for their current HP crushers. This latter path—upgrading—offers a compelling opportunity to unlock better performance and operational benefits without the capital expense of new equipment. Upgrades can help producers meet today’s challenges while also future-proofing their operations. With a wide range of upgrades to choose from, older HP crushers can be modernized with many of the features found on the newer HPe crusher models. Many of these upgrades can also be installed during regular maintenance intervals and planned out easily and cost effectively to not negatively affect production.

Raising production targets 

Reacting to market changes can encourage sites to increase production. Optimization work can help to an extent but may still fall short of the yield gains needed. The HPe Enhanced kinematics upgrade can improve the overall performance of the crusher. The scope of the upgrade kit varies between machine sizes and models but generally involves upgrading several key components. Though requiring some upfront investment, the upgrade can lead to:

• Higher performance in terms of throughput and reduction

• Increases in the crushing forces and horizontal head motion

• Processing the highest possible amount of material per hour while maintaining consistent product output size

Availability gains with less waste

Many plants struggle with the idea of looking to increase production time and equipment availability while minimizing their environmental footprint. Upgrade opportunities that bring production and environmental benefits, however, are available. Traditionally, liner change outs require the use of a backing compound.

With a no-backing liner upgrade this is no longer needed. The upgrade brings sustainability advantages as well as results in more production time due to faster liner changeouts, as drying time for the backing compound is no longer required. Benefits include:

• No need for backing material and related costs

• Eliminates transporting and handling liner backing material

• Up to 50 per cent faster liner changes which means no waiting time for dry out

• Sustainable and safer solution for the operator

Less worries and more equipment life

Properly maintaining your crushing assets can lead to longer equipment and component life, helping to save costs by reducing parts change outs and also defer the need for new machine purchases. Keeping an eye out for early warning signs can help spot issues before they occur. Even when a crusher is initially set up in an optimal way, it does not mean sites can set it up and then forget it. Changes in operating conditions can lead to issues such as excessive fines entering the crusher or feed imbalances which can lead to adjustment ring lift, known as ring bounce.

Undetected this can lead to costly fractures in the adjustment ring or mainframe and cause unplanned downtime and production losses. Many sites still rely on plant personnel to see or “hear” ring bounce manually. However, crushing is loud by nature, and it is easy to mistakenly hear ring bounce or dismiss actual ring bounce as “just how the crusher sounds”.  A more efficient solution is to consider a Ring bounce monitoring upgrade which:

• Protects and analyzes the crusher by detecting adjustment ring movement and warns the operators via the Metso IC70 automation

• Helps prevent extra wearing of parts like main frame seat liners, adjustment ring guide pins and bushings and general overloading of the machine

• Leads to less parts change costs by avoiding wear and tear on parts caused by overloading and shock loads

When site conditions and goals change, all options are on the table but exploring which upgrades are available for your crusher should always be something to consider as it can achieve impressive performance gains while minimizing investment costs.