How we work
At Crusher Consumables, supplying reliable wear parts for crushers and screens starts with understanding the harsh conditions our customers face from the Highveld to the Cape. Our process ensures every jaw plate, cone mantle or screen panel that leaves our yard is ready for tough shifts and South African realities.
Partnering with proven foundries and quality control
We select casting partners with a track record for metallurgical consistency, especially for critical parts like jaw dies, cone mantles, and blow bars. Before any order goes out, our team visits foundries to check melt chemistry, mould integrity, and pattern accuracy. Manganese parts are heat treated by quenching from 1,050 to 1,100 °C to ensure the right austenitic structure for work hardening in the field. We check that pouring and cooling processes meet both our internal standards and OEM profiles. This attention to detail helps prevent premature breakage or unplanned downtime, especially when Eskom power cuts threaten production schedules.
- Metallurgy and heat treatment checked in-plant
- Casting dimensions matched to OEM patterns
- Random sampling for microstructure assessment
- Audit trails maintained for every part batch
Profile matching and pre-dispatch inspection
When a customer sends in worn parts, we physically match profiles and check for deviation against the original chamber or screen design. We use profile gauges and digital callipers to confirm fit, nip angle, and closed side setting compatibility for crushers, and aperture accuracy for screens. Before dispatch, our inspectors flag any issues with casting finish, mounting holes, or lifting lugs. All lifting and handling points are checked for safety compliance to ensure proper installation on arrival. We only ship once a part passes both technical and safety checks, whether it's travelling by bakkie across Gauteng or heading out to a remote Karoo site.
- Compare wear patterns to improve future castings
- Check liner bolt holes for fit
- Confirm all lifting lugs are load-tested
Wear notes and technical handover
Every order includes detailed wear notes from our technical team, drawing on wear profiling and customer feedback. These notes highlight fitment tips, expected work hardening behaviour for manganese, torque advice for bolts and backing compound, and reminders to always defer to the OEM manual for critical values. Where ceramic inserts or special alloys are used, we flag handling and rotor balance implications. Our team notes any unusual wear or feed issues observed during profile checks, helping customers refine choke feeding, toggle setting, or screen tension for longer campaigns. For technical queries or to organise a parts assessment, contact us through our contact form.