What Does a 100 TPH Stone Crusher Plant Include

A complete 100 TPH crushing plant typically contains several coordinated machines designed to break large rocks into uniform aggregates. While layouts vary, the core components are:

1. Primary Crusher (Jaw Crusher)

• The first stage of crushing.
• Reduces large boulders (300–700 mm) into manageable sizes (100–200 mm).
• Known for high durability and the ability to handle hard, abrasive materials such as granite and basalt.

Why it’s essential:

Jaw crushers provide consistent feed sizes for secondary crushers and ensure smooth downstream operation.

2. Secondary Crusher (Cone Crusher or Impact Crusher)

Cone Crusher

Best suited for hard stone (granite, basalt, river stone).

Produces uniform, cubical aggregates with low wear cost.

Impact Crusher

Ideal for medium to soft stone (limestone, gypsum).

Delivers high reduction ratios and excellent particle shape.

3. Vibrating Screen

• Separates crushed material into different size fractions (e.g., 0–5 mm, 5–10 mm, 10–20 mm).
• Usually 2–4 decks depending on output requirements.
• Ensures clean, well-graded aggregate for construction use.

Feeders (Vibrating Feeder / Grizzly Feeder)

• Regulates material flow into the primary crusher.
• Removes fines and improves crushing efficiency.
• Crucial for plant stability and avoiding crusher choking.

Fixed vs. Mobile Crushing Plants

Fixed (Stationary) Plant

• Installed permanently on concrete foundations.
• Best for long-term quarry operations.
• Lower cost, higher stability, and easier maintenance.

Mobile Plant (Wheel or Track Mounted)

• Easily relocatable, no civil works required.
• Preferred for road projects, short-term mining, and urban demolition.
• Higher price but maximum flexibility.

Price Range for 100 TPH Stone Crusher Machines

Pricing for 100 TPH stone crushers varies based on manufacturer, region configuration, and features like automation or eco-friendly additions.

Individual Components:

• 100 TPH Jaw Crusher: $25,000 – $70,000. Entry-level models from Chinese manufacturers start low, while premium ones with advanced wear parts reach higher.
• 100 TPH Cone Crusher: $35,000 – $110,000. Costs rise with hydraulic adjustments and higher durability for abrasive materials.
• 100 TPH Impact Crusher: $30,000 – $90,000. Horizontal shaft impactors are mid-range; vertical ones for finer work add to the price.

Complete 100 TPH Crushing Plant:

Stationary: $100,000 – $280,000.

This includes a basic two-stage setup with jaw, cone/impact, screen, feeders, and conveyors. Advanced models with PLC controls or dust systems push toward the upper end.

Mobile Plant: $130,000 – $380,000.

Wheel-mounted options are more affordable ($130k-$250k), while track-mounted add $50k-$100k for mobility features. Prices from platforms like Alibaba show entry-level mobiles around $140k for basic configs.

Choosing the Right Crusher for 100 TPH Production

For 100 TPH, focus on efficiency, maintenance, and energy use—aim for a 10-15% buffer in capacity to handle peaks.

For Hard Stone (Granite/Basalt):

Opt for a jaw + cone combination. The jaw handles initial compression of abrasive, high-compressive-strength rocks (over 200 MPa), while the cone provides fine reduction and cubical shapes. This setup minimizes wear and ensures durability; e.g., in quarries, it produces road aggregates effectively.

For Soft to Medium Stone (Limestone/Gypsum):

A jaw + impact crusher is ideal. The jaw crushes to intermediate sizes, and the impactor delivers high-quality, shaped products with fewer fines. This is energy-efficient for materials under 150 MPa, common in cement or fertilizer production, where cubical aggregates improve mix quality.

For Recycling:

Choose a mobile impact crusher. These handle concrete, asphalt, or demolition waste, with features like magnetic separators for rebar removal. Mobility allows on-site processing, reducing transport costs; single-chassis units simplify setup for 100 TPH urban recycling projects.

Real-World Examples

Here are three practical configurations drawn from industry cases, illustrating versatility.

100 TPH Stationary Plant for Hard Rock Quarry:

In a Chilean operation, a setup with a PE500x750 jaw crusher, CS75 cone crusher, 3-deck vibrating screen, and belt conveyors processes basalt at ~$160,000. It runs three stages for fine aggregates, producing 0-5mm sand and 5-20mm gravel for construction. Efficiency reaches 95% with low dust via water sprays.

100 TPH Mobile Plant for Limestone Processing:

A wheel-mounted unit in India features a jaw crusher + horizontal impact crusher on a single chassis, costing ~$190,000. Used in road projects, it handles soft limestone to produce 20-40mm chips, with quick relocation between sites enhancing ROI.

100 TPH Track-Mounted Recycling Plant:

For urban demolition in the USA, a mobile impact crusher with integrated screen and magnet, priced at ~$250,000, crushes concrete rubble on-site. It outputs recycled aggregates for backfill, reducing landfill use and transport emissions.