Choosing the right cone crusher is a big decision for your quarry or aggregate production business. This machine is the heart of your secondary and tertiary crushing stages, turning rock into valuable, specific-sized products. A good choice boosts your profit, while a bad one creates bottlenecks and high costs. At ZONEDING, we have helped hundreds of clients find the perfect fit since 1990. This guide will help you understand the options so you can make a smart choice for your operation.

Table of Contents

• What is a Cone Crusher?
• How Does a Cone Crusher Work?
• What are the Types of Cone Crushers?
• Spring vs. Hydraulic: What’s the Real Difference?
• Single vs. Multi-Cylinder: Which is More Advanced?
• How to Select the Right Crusher for Your Rock Type?
• What are Advantages of Equipment from ZONEDING?
• What is the Cost for Cone Crushers?
• What are Features of Cone Crushers from ZONEDING?
• Conclusion

What is a Cone Crusher?

A cone crusher is a compression-type machine that reduces rock by squeezing it. It does not smash rock with impact like an impact crusher. Instead, it crushes material between a rotating piece of steel (the mantle) and a stationary piece of steel (the bowl liner or concave). This machine is a key player in the middle stages of a crushing plant. It takes the larger rock that has already been broken down by a primary jaw or gyratory crusher and makes it much smaller, preparing it for final sizing by a screen or a tertiary crusher. The main goal is to create smaller, well-shaped (cubical) aggregate, which is exactly what concrete and asphalt producers want.

How Does a Cone Crusher Work?

Imagine holding a nut in a metal bowl and using another cone-shaped piece of metal to roll around inside the bowl, cracking the nut against the sides. A cone crusher works in a very similar way. The process is simple but very effective.

What are the Types of Cone Crushers?

There are several types of cone crushers, and each is designed for slightly different jobs. The main differences are in how they are supported, how they handle overload situations (like a piece of uncrushable steel getting in), and how they are adjusted. Understanding these types is the first step in choosing the right machine for your aggregate production.

1. Spring Cone Crusher (Symons Type)

This is the classic, original design for spring cone crushers. It uses a set of heavy-duty springs on the outside of the machine to protect it from damage. If a piece of metal or extremely hard rock enters the crusher, the springs compress, allowing the bowl to lift up and let the object pass through.

Advantages:

• Simplicity and Durability: They have a simple mechanical design that is easy to understand and maintain. They are known for being very tough.

• Lower Initial Cost: Spring cone crushers are generally less expensive to buy than their hydraulic counterparts.

Applications:

They are excellent for small to medium-sized quarries and mining operations, especially where budgets are tight and advanced automation is not a priority. They perform well in secondary crushing applications with medium-hard rocks.

2. Single-Cylinder Hydraulic Cone Crusher

This is a more modern design that replaces the springs with a single large hydraulic cylinder cone crusher at the bottom of the crusher. This cylinder supports the main shaft and is used for both adjusting the CSS and providing overload protection.

Advantages:

• Easy Adjustment: You can adjust the setting with the push of a button, which is much faster and safer than adjusting springs manually.
• Good Performance: They offer a high crushing ratio and produce a good product shape. The design is less complex than a multi-cylinder crusher.

Applications:

This is a very popular choice for a wide range of applications, from crushing hard rock like granite to processing river stone. It is a versatile workhorse for secondary and tertiary crushing stages in modern plants.

3. Multi-Cylinder Hydraulic Cone Crusher

This is the high-performance option. It uses multiple hydraulic cylinders around the base of the crusher. These cylinders handle both adjustment and overload protection. The design also features a fixed main shaft, which makes the structure very stable.

Advantages:

• Superior Crushing Force: The stable design allows for higher speeds and greater crushing force, leading to higher throughput and excellent product shape (high cubicity).
• Advanced Automation: These crushers are often equipped with sophisticated control systems that automatically adjust settings for optimal performance. ZONEDING uses Siemens PLC systems for this.

Applications:

This is the best choice for high-capacity quarries and mines that process very hard and abrasive materials like basalt, granite, or iron ore. It is the top performer for producing premium aggregates.

4. Gyratory Crusher

A gyratory crusher works on the same principle as a cone crusher, but it is much, much larger. It is almost always used as a primary crusher, not a secondary one. It has a less steep crushing head than a cone crusher, allowing it to accept very large feed sizes directly from the quarry.

Advantages:

• Extremely High Capacity: They can process thousands of tons of rock per hour.
• Handles Large Feed: They can take very large boulders directly from a blast, reducing the need for preliminary breaking.

Applications:

These are only found in very large-scale mining operations and the biggest quarries in the world, where production demands are massive.

5. Mobile Cone Crusher

This is not a different type of crushing mechanism, but a platform. A mobile cone crusher is a single-cylinder or multi-cylinder hydraulic unit mounted on a tracked chassis. This creates a self-contained, movable crushing plant.

Advantages:

• Flexibility: You can easily move the crusher around a large quarry or transport it between different job sites.
• Fast Setup: It eliminates the need for concrete foundations and can be up and running very quickly.

Applications:

This is ideal for contractors, recycling operations, and quarries that need to move their crushing operations frequently. It is a key component of a complete mobile crushing and screening plant.

Spring vs. Hydraulic: What’s the Real Difference?

The biggest evolution in cone crusher technology has been the shift from springs to hydraulics. While spring crushers are still reliable, hydraulic cone crushers offer major advantages for most modern operations. The core difference is how they handle adjustments and protect themselves from damage.

With a spring crusher, you have to manually tighten or loosen huge bolts to change the CSS. For overload protection, the springs physically compress. This works, but it can be slow and less precise. A hydraulic system uses oil pressure to do everything. You can adjust the CSS from a control panel in minutes. For overload, the hydraulic system allows oil to be released from the cylinder, letting the uncrushable object pass, and then it automatically returns to the previous setting. This means less downtime, better safety for your crew, and more consistent product size. For most new plants, a hydraulic crusher is the smarter long-term investment.

Single vs. Multi-Cylinder: Which is More Advanced?

Both single-cylinder and multi-cylinder are types of hydraulic cone crushers, but the multi-cylinder design is generally considered more advanced and high-performing. A single-cylinder crusher supports the main shaft assembly from one large cylinder at the bottom. This is a simpler and very robust design.

A multi-cylinder crusher has a main shaft that is fixed in place. The bowl assembly moves up and down for adjustment, pushed by several hydraulic cylinders. This design provides more uniform support and allows for a much larger crushing force to be applied. The result is higher throughput, a better reduction ratio, and a more cubical final product. If you are processing very hard rock or have strict specifications for your final product shape, a multi-cylinder hydraulic crusher is the superior choice. If you need a reliable, modern, and slightly more economical option, the single-cylinder is an excellent machine.

How to Select the Right Crusher for Your Rock Type?

The type of rock you are crushing is the most important factor in your decision. Different rocks have different hardness and abrasiveness, which affects how they break and how quickly they wear down your machine’s parts.

• For Hard, Abrasive Rock (Granite, Basalt, Quartzite): You need a machine built for this kind of punishment. A multi-cylinder hydraulic cone crusher is the best choice. Its high crushing force is needed to break these rocks efficiently. You also must pay close attention to the wear parts. At ZONEDING, we use high-manganese steel (Mn18Cr2) for our mantles and bowl liners to ensure they last as long as possible.
• For Medium-Hard Rock (Limestone, Dolomite, Andesite): These rocks are easier to crush. A single-cylinder hydraulic cone crusher is often the perfect balance of performance and cost. A modern, well-maintained spring cone crusher can also be a good, economical option for these materials.
• For Softer Rock or Gravel (Shale, River Pebbles): The main goal here is often shaping, not just size reduction. You want to avoid creating too many flat, flaky particles. A multi-cylinder crusher running at a higher speed is excellent for producing the highly cubical aggregate needed for high-quality concrete and asphalt.

What are Advantages of Equipment from ZONEDING?

At ZONEDING, we understand that your equipment is the heart of your operation. We provide complete, reliable solutions for your limestone crushing plant.

• One-Stop Solution: We can design and supply the entire processing line, from the primary limestone crusher machine to the final conveyors. This ensures all the parts work together perfectly.
• Customized Design: Every quarry is different. We design your plant layout based on your specific limestone characteristics, your site conditions, and your production goals.
• Durability and Reliability: We use high-wear-resistant steel and components from trusted brands to build machines that can handle the tough job of crushing rock day after day.
• Factory-Direct Value: As the manufacturer, we sell directly to you. This removes the middleman and allows us to offer competitive prices without sacrificing quality.

What is the Cost for Cone Crushers?

The price of a cone crusher can range from as low as $30,000 for a small, Chinese-made spring cone crusher to over $500,000 for a large, high-capacity multi-cylinder hydraulic crusher from a top global brand. This wide range is due to several factors.

• Type and Size: A large multi-cylinder hydraulic crusher will always cost much more than a small spring crusher.
• Technology: Advanced automation systems with PLCs and sensors add to the cost but also improve efficiency.
• Components: The brand of the motor, bearings, and electronics makes a difference. We use trusted brands like Siemens and Schneider to ensure reliability.
• Manufacturer: As a direct manufacturer, ZONEDING can offer a better price than a dealer or distributor because there is no middleman. We provide a strong price-to-performance ratio by combining robust design with efficient production.

What are Features of Cone Crushers from ZONEDING?

At ZONEDING, we build our cone crushers to be reliable, efficient, and easy to maintain. We combine proven designs with high-quality components to give you the best value.

• Robust Construction: Our crushers use a heavy-duty frame and high-strength forged main shaft to handle the toughest rocks without failing.
• High-Quality Wear Parts: We use high-manganese (Mn18Cr2) or other customized alloys for our mantles and bowl liners. This means you spend less time changing parts and more time crushing. Our unique crushing chamber designs also improve efficiency and liner life.
• Advanced Hydraulic Systems: Our hydraulic systems provide quick, safe adjustments and reliable overload protection. This protects your investment and minimizes downtime.
• Premium Components: We use high-quality motors, bearings, and electrical components from world-renowned brands like Siemens, Schneider, and ABB to ensure our machines run smoothly and reliably for many years.
• Customization: We understand that every quarry is different. We can work with you to customize the crusher’s configuration, including the chamber type and motor size, to perfectly match your specific application and aggregate crushing plant layout.

Conclusion

Choosing the right cone crusher comes down to matching the machine’s technology to your rock type, production goals, and budget. For hard rock and high-capacity needs, a multi-cylinder hydraulic crusher is the top choice. For all-around versatility and modern performance, a single-cylinder hydraulic crusher is an excellent investment. The classic spring cone crusher remains a solid, low-cost option for smaller operations with less demanding materials.

Your next step should be to clearly define your needs. Know your feed material, the input and output sizes you require, and your target tons per hour. With this information, you can have a productive conversation with an equipment expert who can guide you to the perfect model.

Contact us today to discuss your project. Our engineers are ready to help you select the cone crusher that will make your quarry more profitable.