Plant
Apron Feeder Line
Apron and chute lines that concentrate wear on buttons and tiles.
Parts for this plant
See our wear notes and printable resources for planning liner changes.
Apron feeder line setup and output
Apron feeder lines are a backbone for many South African crushing operations, especially in quarries and mines handling abrasive or heavy materials. These systems consist of heavy-duty steel pans or flights bolted to robust chains, forming a moving bed that delivers bulk rock or ore from a feed hopper to the primary crusher or screening area. The apron feeder manages even, controlled feed rates to prevent surges and ensure downstream equipment isn't overloaded.
Material is loaded into the feed hopper, then steadily transferred by the apron feeder. This setup is geared towards handling high-impact, coarse feed, from blasted rock in the Highveld to denser aggregate from the Karoo. Output is typically consistent, with a focus on reliable feed quality rather than size reduction at this stage.
Wear hotspots on aprons and chutes
In this circuit, wear is most severe where rock first contacts steel: the feed hopper’s impact zone and the first few metres of the apron itself. Hard lumps and fines alike batter these surfaces. Chute lines, particularly transitions and turns, also see high abrasion as material scours along liners, sometimes concentrating at changes in direction or where material speed increases.
Wear buttons and ceramic tiles are used to take the brunt of this punishment. Buttons, installed in high-impact scatter patterns, absorb direct hits and delay liner wear, while tiles resist sliding abrasion and protect flat areas. Without these, mild steel liners in the hopper or apron quickly thin out and risk breakthrough, causing unplanned stoppages.
Wear buttons and hopper liners from Crusher Consumables
Our Wear Button Pack includes tough, alloyed steel or ceramic buttons designed for easy field welding onto high-wear surfaces. These buttons act as sacrificial shields, taking impact and abrasion before the main liner is affected. They are especially useful on apron flights and in feed hoppers, where targeted placement can double or triple liner life in the harshest conditions.
Feed Hopper Liners, available in high manganese, chromium carbide, or ceramic-faced options, provide broad-area protection. These are precision cut to suit OEM profiles and come pre-drilled or ready to weld, depending on your plant’s configuration. Together, wear buttons and hopper liners form a layered defence: buttons handle direct hits and high points, while the liner absorbs general abrasion. Correct installation, using proper backing compound and torque on liner bolts, is vital for safe operation and to avoid liner movement.
- Wear Button Pack: spot protection for severe impacts
- Feed Hopper Liner: full coverage against abrasion
- Custom profiles and thickness options for all major apron feeders
Planning liner changes and stock for power cuts
Liner maintenance on apron feeders needs careful scheduling, especially with Eskom power cuts disrupting planned shutdowns. To avoid forced downtime, campaign your liner changes around crusher maintenance intervals and stock holding on site. Keep a minimum stock of wear button packs and at least one full set of hopper liners per chute on hand, as unexpected breakthrough in the impact zone can halt the whole line.
During any liner change, use safe lifting practices with certified lugs and follow lockout procedures. After liner replacement, check for proper fit and torque, and run a short test feed to confirm all fastenings hold under load. For plants exposed to Durban humidity or Cape southeaster conditions, check for liner corrosion during shutdowns. Use our contact form to organise restocking or discuss liner upgrades suited to your specific apron feeder model.
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