“How much does a crusher cost?” and “what does it cost to set up a crushing and screening plant?” are the first questions anyone planning a quarry or mining investment asks. There is no single answer: two plants of the same capacity can differ greatly in price depending on crusher type, product range, site conditions and equipment quality. And the right basis for comparison is not just the purchase price but the total cost per tonne over the life of the plant.
In this guide we explain the main factors that determine crusher and crushing plant prices, investment and operating cost items, the mobile versus fixed comparison and the information you need to prepare to get an accurate quote. Note: Market prices change frequently with exchange rates, steel prices and demand, so this article gives no figures and explains the factors that drive cost.
Factors That Determine Crusher Price
| Factor | Effect on Price |
|---|---|
| Crusher type | Jaw crushers are relatively simple; cone and VSI crushers contain more complex mechanical and hydraulic systems |
| Size and capacity | Price rises with opening size, motor power and machine weight |
| Material and build quality | Body steel, casting quality, bearing and bushing brands, heat treatment and machining precision |
| Hydraulics and automation | Hydraulic setting, tramp protection, automatic lubrication and control systems |
| Wear part metallurgy | Manganese grade and alloy options affect both the initial price and the operating cost |
| New or used | Used is cheaper but carries overhaul and parts risk |
| Lead time and stock | Delivery from stock or urgent manufacture can affect price |
For the differences between crusher types see our what is a crusher guide, and for jaw crusher sizes our jaw crusher sizes guide.
Crushing and Screening Plant Cost Items
A crushing and screening plant is more than a crusher. The total investment consists of:
| Item | Content | What Affects the Cost |
|---|---|---|
| Main equipment | Crushers, screens, feeder, hopper | Capacity, number of stages, number of products |
| Material handling | Belt conveyors, chutes, stacking conveyors | Number and length of conveyors, belt width |
| Steelwork | Platforms, frames, walkways, stairs | Plant height and layout |
| Civil works | Foundations, retaining walls, hopper concrete, site levelling | Ground, topography, level differences |
| Electrics and automation | Transformer, panels, cabling, control system | Installed power, distances, level of automation |
| Washing and water (if any) | Screw washer, hydrocyclone, thickener, ponds | Clay content, water source |
| Dust and noise control | Water sprays, enclosures, filters | Environmental conditions, distance to settlements |
| Installation and commissioning | Cranes, erection crew, testing | Plant size, site access |
| Permits and engineering | Licences, EIA, design | Site and legislation (quarry licensing guide) |
For details of plant planning see our crushing and screening plant set-up guide.
Mobile Crusher or Fixed Plant?
| Criterion | Mobile Crusher | Fixed Plant |
|---|---|---|
| Initial investment (same capacity) | Equipment price usually higher | Equipment more economical; civil works and installation added |
| Set-up time | Very short | Longer |
| Flexibility | High; can be relocated | Low |
| Operating cost | Diesel consumption, track and engine maintenance | Grid electricity; usually lower cost per tonne |
| Suitable for | Temporary jobs, recycling, sites where the face advances | Long-life, high-capacity quarries |
For a detailed comparison see our mobile or fixed guide.
Operating Cost: Where the Real Difference Lies
Over the life of a crushing plant, the money spent often exceeds the initial investment. The main operating items are:
- Energy: Crushers, screens, conveyors and pumps; tracked as kWh per tonne (energy efficiency guide).
- Wear parts: Jaw plates, mantles–concaves, blow bars, screen wire, conveyor idlers. Rock abrasiveness determines this item (wear materials guide).
- Maintenance and spare parts: Bearings, bushings, belts, seals, hydraulic parts (crusher spare parts guide).
- Loading and haulage: Hauling from the face to the plant is often the largest item (loading and haulage guide).
- Personnel and downtime: Unplanned stoppages, lost production and urgent parts costs.
So when comparing two quotes, look not only at the machine price but also at design capacity, expected wear cost, energy consumption and parts and service support.
Cost of Opening a Quarry
A quarry investment includes, beyond the crushing plant: land and licensing processes, geological survey and drilling, overburden removal, road building, a fleet of drills, excavators, loaders and trucks, a weighbridge, offices and restoration obligations. For the planning steps see our quarry planning guide.
Information Needed for an Accurate Quote
- The material to be processed (rock type, test results if available, moisture and clay),
- Maximum feed size,
- Target capacity (t/h) and daily operating hours,
- Required products and fractions (e.g. 0–5, 5–12, 12–19, 19–25 mm),
- Fixed or mobile preference,
- Site information: area, level differences, power and water,
- Existing equipment and integration needs.
A quote prepared with this information lets you make a realistic comparison of capacity and cost.
Common Mistakes When Comparing Prices
- Comparing nominal capacities without checking them against the real material and products.
- Not checking whether screens, conveyors and steelwork are in the scope of the quote.
- Ignoring electrics, civil works and installation.
- Overlooking wear part and spare parts costs.
- Not asking about after-sales service and parts availability.
Frequently Asked Questions
Why do crusher prices vary so much?
Crusher type, size, build quality, hydraulic and automation equipment, wear part metallurgy and delivery terms change the price significantly.
Is it possible to set up a small crushing plant?
Yes. For low-capacity work, compact plants with one crusher and one screen, or mobile crushers, can be used.
Does buying a used crusher make sense?
It can with proper inspection; body cracks, bearing and bushing condition, wear parts and parts availability should be checked by a specialist.
How long does it take to prepare a quote?
With complete information, an equipment quote can be prepared quickly; turnkey plant projects may need a site visit.
How to Calculate Cost per Tonne
The soundest way to compare two plant or equipment quotes is to estimate total cost per tonne. A simple approach:
| Item | Calculation |
|---|---|
| Investment (depreciation) | Total investment / total tonnes produced over the expected life |
| Energy | kWh/t × electricity price (for mobile, litres/t × fuel price) |
| Wear parts | Part cost / tonnes processed over the part’s life |
| Maintenance and spare parts | Annual maintenance budget / annual production |
| Personnel | Annual personnel cost / annual production |
| Downtime | Unplanned downtime hours × hourly value of lost production |
Comparisons made with this table often show that more expensive but more efficient and durable equipment becomes more economical within a few years. Keeping wear records is the basis of this calculation (crusher spare parts guide).
Field Example: The Hidden Cost of a Cheap Quote
Suppose an investor compares two quotes. In the cheaper one, the screen area is small, the conveyors are narrow and crusher power is borderline. Once the plant is commissioned, the screens are overloaded, the product is out of specification and capacity falls short of the target. The screens and conveyors added later cost more than the difference between the two quotes. Quotes should therefore be compared on flowsheets prepared with the same material and product assumptions.
Glossary
- Turnkey: A quote covering design, fabrication, installation and commissioning.
- Flowsheet: A diagram showing material flow between equipment and capacities.
- Installed power: The total power of all motors in the plant.
- kWh/t: Energy consumption per tonne.
- Availability: The share of planned time in which the plant is able to run.
More Questions
How long does it take to set up a crushing plant?
Equipment manufacture, civil works and installation times vary with plant size; mobile plants can be commissioned much faster.
What determines conveyor belt and screen wire prices?
Belt width, carcass and cover type, and for screen wire the aperture, wire diameter and wire material are the main factors (screen wire sizes, conveyor spare parts).
Does renting a mobile crusher make sense?
It can for short-term, temporary jobs, or to trial capacity and products before investing.
CSP Mühendislik Support
CSP Mühendislik provides turnkey solutions for the design, fabrication, installation and commissioning of crushing and screening plants. You can browse our equipment on our products page and use our spare parts and service, maintenance and repair support during operation.
