A crusher operator is the person who keeps the crushers, screens, feeders and conveyors of a crushing and screening plant running safely and efficiently, monitors production and makes the first response. The plant’s capacity, product quality, wear part life and, above all, safety depend to a large extent on the operator’s knowledge and attention.
In this guide we look at the crusher operator’s duties, start-of-shift and in-shift checks, required training and certification, crushing and screening plant safety instructions and an example risk assessment table. Note: Certification and training obligations vary by country and legislation; current regulations and the assessment of the site’s safety specialist should be followed. Turkish requirements are given as an example.
Duties of a Crusher Operator
- Checking at the start of the shift that the equipment is ready to run,
- Starting and stopping the plant in the set sequence (generally starting from the end of the flow towards the beginning, and stopping from the beginning towards the end),
- Ensuring steady feed of suitable size to the crusher; coordinating with the loader or excavator operator,
- Monitoring crusher setting, motor current, oil pressure and temperature,
- Watching product quality (size, fines) and reporting deviations,
- Responding according to procedure to bridging, blockages and uncrushable metal,
- Spotting and reporting failure signs (noise, vibration, heat, leaks) early,
- Keeping shift records and handing over the shift,
- Keeping the plant orderly and clean and ensuring safety rules are followed.
Start-of-Shift Checklist
| Equipment | Check |
|---|---|
| General | Are guards in place, do emergency stop buttons and pull cord switches work, are unauthorised people nearby? |
| Crushers | Oil level, lubrication unit, grease points, wear part condition, loose bolts, setting |
| Cone crusher | Oil pressure and temperature, hydraulic system, dust seal (lubrication unit) |
| Screens | Screen wire and panels, tension, springs, bearing temperature (vibrating screen) |
| Conveyors | Belt tracking, idlers, scrapers, skirt rubber, belt splices (belt conveyor) |
| Feeder and hopper | Grizzly bars, liners, springs, bridging |
| Belts and drives | Belt tension, pulley guards, gearbox oil level |
| Dust suppression | Are water sprays and nozzles working? |
For a preventive maintenance schedule for crushers see our crusher spare parts guide and predictive maintenance guide.
Points to Watch During Operation
- Steady feeding: Keep the crusher opening full but not overflowing; choke-fed operation for cone crushers.
- Motor current: Sudden rises indicate overfeeding or blockage.
- Oil temperature and pressure: Deviations from normal values must be reported immediately.
- Uncrushable metal: Parts such as bucket teeth and drill bits can seriously damage the crusher and belt (magnetic separator and metal detector).
- Product check: Oversize product can indicate torn screen wire or crusher wear (sieve analysis).
Required Training and Certification
Crushing and screening plants and quarries are generally classed among very hazardous workplaces in occupational safety legislation. Therefore, for operators:
- Occupational health and safety training: In Turkey, under Occupational Health and Safety Law No. 6331 and related regulations, training must be given before starting work and periodically; duration and frequency are set by regulation according to the workplace hazard class.
- Vocational training and qualification certificates: Depending on the nature of the job, master/journeyman certificates under the Ministry of National Education or Vocational Qualifications Authority (MYK) certificates may be required. Which occupations require certification should be checked in current legislation and the relevant lists.
- If mobile plant is used: Employees operating loaders, excavators or forklifts must hold the relevant operator certificates.
- Machine-specific training: Operation and maintenance training from the equipment manufacturer or supplier.
- Health surveillance: Periodic health checks because of exposure to dust and noise.
Crushing and Screening Plant Safety Instructions
The points below are an example of a safety instruction to be prepared for operators in a crushing and screening plant. The instruction should be adapted to the plant by the safety specialist according to the site’s risk assessment.
- Personal protective equipment (hard hat, safety boots, glasses, ear protection, dust mask, high-visibility vest) will be worn at all times.
- Running machines, the crusher opening, screen decks and conveyor belts will never be touched.
- Before maintenance, cleaning, clearing blockages and changing parts, power will be isolated, lockout–tagout (LOTO) applied and the zero-energy state verified.
- Stone bridging in the crusher opening will be cleared only with suitable equipment (e.g. a hydraulic rock breaker) and the set procedure; no one will enter or climb onto the crusher opening.
- Equipment will not be run with machine guards removed.
- Spillage under and beside conveyors will not be cleaned while the belt is running.
- No one will climb onto stockpiles, especially those being drawn from below (stockyard safety).
- Traffic rules set for mobile plant and trucks will be obeyed; no one will stand in blind spots.
- Guardrails and safety harnesses will be used when working at height.
- During blasting times, everyone will withdraw to designated safe areas.
- Failures, near misses and accidents will be reported immediately.
For detailed measures see our guide to occupational safety in quarries and crushing plants.
Example Risk Assessment Table
| Hazard | Risk | Control |
|---|---|---|
| Conveyor pulley and idler nip points | Limb entrapment, serious injury | Guards, pull cord switch, LOTO, training |
| Crusher opening | Flying stones, falls, entrapment | Fly-rock curtains, platform guardrails, no entry into the opening |
| Unexpected start-up during maintenance | Serious injury | Lockout–tagout, energy verification |
| Silica (quartz) dust | Lung disease | Dust suppression, enclosed transfers, suitable masks, health surveillance (dust control) |
| Noise | Hearing loss | Enclosures, rubber liners, ear protection, measurement |
| Mobile plant and truck traffic | Crushing, collision | Traffic plan, pedestrian routes, reversing alarms |
| Work at height | Falls | Guardrails, stairs, safety harnesses |
| Electricity | Electric shock | Authorised electricians, panel locks, earthing |
| Lifting heavy parts | Falling loads | Suitable lifting equipment and plan, trained personnel |
Suggested Shift Record Form
- Operating hours and production quantity (if there is a belt scale),
- Crusher setting and changes made,
- Oil temperature and pressure readings,
- Stoppages and their causes,
- Tramp (metal) events,
- Failure signs observed and reports made,
- Wear parts changed.
Frequently Asked Questions
What does a crusher operator do?
Runs the crushing and screening plant, monitors feed and machines, tracks product quality, makes the first response and ensures safety rules are applied.
Does a crusher operator need a certificate?
Occupational safety training is mandatory; depending on the job and the country, vocational training or qualification certificates may also be needed. Current obligations should be confirmed with the legislation and the safety specialist.
How is stone stuck in the crusher opening cleared?
After the crusher is stopped and safety measures are taken, only with suitable equipment and according to a written procedure; no one should enter the crusher opening.
What are the most common causes of accidents in crushing plants?
Touching running conveyors, not isolating power during maintenance, mobile plant traffic and falls from height are among the most common causes.
Plant Starting and Stopping Sequence
To prevent material build-up and blockages, crushing and screening plants are started and stopped in a set sequence:
| Operation | Sequence | Why? |
|---|---|---|
| Starting | Stockpile conveyors → screens → crushers → feeder | Material is not sent until downstream equipment is ready |
| Stopping | Feeder → crushers once empty → screens → conveyors | Equipment is emptied before stopping; starting under load is avoided |
| After an emergency stop | No restart until the cause is cleared and checks are made | Full crushers and conveyors are strained on start-up |
On cone crushers, the lubrication unit is started before the crusher and the crusher is started once oil pressure and temperature reach suitable values; when stopping, lubrication continues for a while after the crusher stops. The exact sequence follows the manufacturer’s instructions.
Field Example
At one plant, an employee trying to clean up spillage under a running conveyor gets an arm close to the return pulley; thanks to the pull cord switch the belt is stopped immediately and the event is recorded as a near miss. After investigation, pulley guards are extended, scrapers and skirt rubber are renewed to reduce spillage, and the rule that cleaning is done only under lockout–tagout is reinforced with training. This example shows the importance of reporting near misses in preventing serious accidents.
Glossary
- LOTO (lockout–tagout): Isolating, locking and tagging energy sources before maintenance.
- Pull cord switch: An emergency stop wire along a conveyor that stops the belt when pulled.
- Near miss: A dangerous event that passes without injury.
- Risk assessment: Identifying hazards, rating risks and planning controls.
- PPE: Personal protective equipment.
- Tramp: Uncrushable metal or parts entering the crusher.
More Questions
Can a crusher operator carry out maintenance?
Daily checks and simple maintenance tasks can be done; extensive mechanical, hydraulic and electrical work should be carried out by authorised, trained maintenance personnel under LOTO.
Which records should the operator keep?
Operating time, setting changes, oil readings, stoppages, tramp events and observed failure signs should be recorded.
Who carries out the risk assessment in a crushing plant?
A team made up of the safety specialist, workplace doctor and employee representatives acting for the employer; operators’ site experience should always be part of this work.
CSP Mühendislik Support
CSP Mühendislik can provide hands-on training for operator and maintenance teams in crushing and screening plants on equipment operation, wear monitoring, lubrication and safe part replacement, and supports the supply of machine guards and safety equipment. See our service, maintenance and repair page for maintenance services and our spare parts page for parts. For crusher types see our what is a crusher guide.
