Today
Settings follow habit and campaign rules
- Speed and gap are often set once per material campaign.
- Rate, energy and gradation are rarely scored together before a change.
- The same logic may be reused when feed character shifts.
One setting move can shiftrate, power and gradation together.
Rotor speed and gap width set how hard the crusher works and what size leaves the circuit. INSUS uses crusher and quality history you already keep to recommend material-aware settings for the operator to review, without taking control of the machine.
01
Throughput, energy and size move together.
02
Feed material changes the sweet spot.
03
Recommendations stay with the operator.
The problem
Fixed campaign settings hidethe real trade-off.
Rotor speed and outlet gap affect tonnes, kWh per tonne and product gradation at once, and the balance shifts with feed. When settings are locked at campaign start or tuned from experience alone, the plant may run safe but not efficient, or chase rate and miss size until lab results catch up.
01Rotor speed and gap set the operating point
02Throughput and energy move with every change
03Gradation may confirm the miss late
- 01Rotor speed and gap set the operating point
- 02Throughput and energy move with every change
- 03Gradation may confirm the miss late
The shift
From fixed campaign settingsto material-aware advice.
The operator stays in charge of the crusher. What changes is whether a candidate setting is reviewed against this plant's history for the feed in use before it is applied.
With INSUS
Preview the trade-off before you move
- Candidate settings are scored for throughput, energy and predicted gradation.
- Recommendations reflect the feed material currently being crushed.
- The operator reviews and applies changes on the existing control system.
How it works
From crusher historyto a setting recommendation.
This fits OptiStudio as operational decision support beside the plant's existing DCS or PLC. Day one is advisory: recommendations do not write setpoints to the crusher.
Connect
Bring crusher and quality data together
Read-only links to crusher DCS or PLC tags, historian records and gradation tests: rotor speed, gap width, feed rate, motor power, feed material and measured product size.
Understand
Learn how each feed responds
Learn how settings have related to throughput, energy and gradation for the materials this plant actually runs, not from a generic crusher template.
Predict
Preview the effect of a setting change
Estimate expected impact on rate, power and product size before a candidate speed or gap is applied.
Advise
Rank settings inside quality limits
Rank rotor-speed and gap options by estimated energy and rate while staying within predicted gradation targets. The operator decides what to apply.
Verify
Check advice against actual results
Compare recommendations with measured throughput, power and gradation, then recalibrate the plant- and material-specific model.
Getting started
Start with one crusherand the tags you already log.
For aggregates plants that already record crusher operating data and product-gradation results. Delivered through OptiStudio as advisory circuit decision support. Expert Services can help with discovery and pilot validation. No new plant-floor sensors are assumed where DCS, power and lab data already exist.
- What we need. Rotor speed, gap width, feed rate, motor power, feed material identity, and matching product-gradation results from existing systems.
- What you see first. Material-specific setting recommendations that preview throughput, energy and predicted gradation before the operator changes the machine.
- How it grows. After validation on one crusher, extend to additional circuits and feeds as production and quality history support it.
Related for aggregates
Other aggregatesstarting points
Circuit setpoints sit beside blast feed quality and wear-part timing on the same quarry.
- 01Aggregates Blast Fragmentation OptimizationRecommend blast design adjustments from blast and crusher history so fragmentation matches what the primary circuit needs.
- 02Aggregates Wear-Part Predictive MaintenanceEstimate wear-part replacement timing for quarry loaders and excavators from usage and maintenance history.
- 03Aggregates industryThe wider picture for quarry crushing, screening, inventory and maintenance.
Questions aggregates process teams ask us
Crusher settings move throughput, energy and product size together, and the balance changes with feed. This use case recommends material-aware settings from plant history so operators can review the trade-off before changing the machine.
Primarily rotor speed and outlet gap width, constrained to ranges expected to keep predicted gradation within the plant's product target.
Rotor speed, gap width, feed rate, motor power, feed material type, and matching product-gradation test results from existing DCS, historian and quality systems.
No. The pilot is scoped to data modern crushing plants already collect. If a critical tag or lab link is missing, that is identified in discovery.
No. Integration is read-only decision support. The operator reviews recommendations and applies changes on the existing control system. There is no closed-loop setpoint write on day one.
Candidate settings are scored against predicted gradation before recommendation. Advice can be limited to options expected to stay in specification.
Through OptiStudio as operational decision support for crusher circuits. Expert Services can support discovery, data readiness and pilot validation against the plant's own baseline.
Aggregates · Crushing & screening
See the trade-off before you change the setting.
Use crusher and quality history you already keep to review material-specific setting advice for throughput, energy and gradation. The operator stays in control of the machine.