Mobile Crushers vs Stationary Crushing Plants: What is the Difference?

Today’s construction and mining tasks require the need for crushers that play a crucial role in reducing large rocks into smaller, manageable pieces for further processing, and understanding their key differences is essential for making the best choice for your project needs. At first glance, it’s obvious that stationary equipment is fixed, while mobile equipment can be moved to the construction site. However, let's dive into the specifics, discussing each type's advantages and disadvantages!

What is a Mobile Rock Crusher

A mobile rock or stone crusher is a portable machine designed to reduce the size of rocks and stones. These crushers are mounted on a mobile platform or chassis, allowing them to be transported easily from one location to another. Mobile crushers can be wheeled or tracked and operate in a variety of environments, making them highly versatile and convenient for projects that require frequent relocation. 

As the authorized dealer of Powerscreen, you can get to choose from our fleet of brand-new Powerscreen jaw crushers, known for their robust design, high performance, and efficiency in mobile applications. You also benefit from comprehensive warranties, access to genuine spare parts, and after-sale services.

What is a Stationary Crusher

A stationary crusher, also known as a fixed crusher, is designed to stay in one place throughout its operating life. These crushers are typically installed in a designated area at a mining or quarry site and remain there until the end of the project's life cycle. Stationary crushers are known for their larger capacity and ability to handle massive volumes of material.

Pros and Cons of Stationary and Mobile Crushers

While both mobile and stationary crushers perform the same basic function—crushing rocks into smaller pieces—each type is characterized by a number of features.

What makes mobile crushers stand out?

Mobility: Mobile crushers can move and rotate on site. Although their speed is relatively slow, and they are limited by how far they can go —often needing to cool down every 10 to 15 minutes—their mobility can cut the cost of transportation to zero. This feature is valuable in rough terrains where cranes and low-beds do not have easy access to the site.

Quick Setup: Due to the fast installation, they can be operational quickly and are ideal for temporary projects, or when starting operations rapidly is crucial.

Space-saving and Integrated Systems: Mobile equipment has a compact structure, and integrates a feeder, belt conveyor, crusher, and vibrating screen, all in one frame, which reduces the space requirements. 

Reduced Environmental Impact: By minimizing material transportation, mobile crushers can help process materials directly at the extraction site. Less hauling means fewer carbon emissions and a smaller footprint.

Cost Efficient: Its mobility reduces the need for additional infrastructure, such as haul trucks, and it requires less transporting vehicles than the stationary crusher. For example, you may need two machines to transport a mobile crusher to the mining site whereas around 10 equipment are required to dismantle and install the stationary crusher.

Versatile Applications: Suitable for a wide range of crushing tasks, including recycling, demolition, and small-scale mining operations.

Limitations of mobile crushers

Lower Capacity: Generally have a lower production capacity due to the smaller size and lighter build that limit the crushing mechanisms that can be used, resulting in less crushing force.

Limited Customization: Less room for customization compared to stationary setups.

What makes stationery crushers stand out?

High Production Capacity: Able to handle large volumes of material, making them suitable for major projects and high-demand applications.

Customization: Can be tailored to meet specific project requirements and integrated into larger processing systems.

Consistency: Provide a steady and reliable output, essential for continuous, large-scale production.

Economies of Scale: Higher initial investment can be offset by lower operating costs and increased production efficiency over time.

Durability: Built to last, stationary crushers are designed to withstand the rigors of high-capacity crushing tasks.

Disadvantages of Stationary Crushers:

Lack of Mobility: Once installed, these crushers are fixed in place, requiring significant effort and cost to relocate.

Longer Setup Time: Installation is more time-consuming and involves significant site preparation.

Higher Initial Cost: The initial setup and infrastructure costs can be higher due to the need for foundations and permanent installations.

Decision-Making Considerations

When deciding between a mobile rock crusher and a stationary crusher, consider the following factors to ensure you make the best choice for your project:

Project Size and Duration

For projects that are short-term or involve smaller volumes of material, mobile crushers are often the best choice due to their quick setup and ease of relocation. They allow for rapid deployment and can be operational within hours, which is ideal for projects with tight timelines. For example, a road construction project requiring temporary crushing of asphalt might benefit from a mobile crusher. On the other hand, large-scale, long-term projects, such as a quarry producing aggregate for several years, benefit more from the high capacity and efficiency of stationary crushers. These crushers can handle larger volumes over extended periods, making them more suitable for sustained, high-output operations.

Material Types and Sizes

Different types of materials and their sizes significantly influence the choice of crushing equipment. Mobile crushers offer versatility in handling a variety of materials, from concrete and asphalt to natural stones and minerals. They can quickly adapt to different crushing needs on-site. Stationary crushers, however, are ideal for handling large, heavy, and abrasive materials that require a consistent and powerful crushing force.

Initial and Operating Costs

Initial and operating costs are crucial factors to consider. Mobile crushers generally have lower initial costs due to their minimal infrastructure requirements and quicker setup times. They also offer operational cost savings by reducing material transportation needs. However, they might have higher maintenance costs due to frequent relocation and operational wear. Stationary crushers have higher upfront costs for site preparation and installation but tend to have lower operating costs over time due to their robust design and higher efficiency in handling large volumes of material.

It's also important to note that many sites can benefit from using both mobile and stationary crushers. Even a project with a stationary crusher can improve efficiency by renting a mobile crusher, particularly for tasks that require flexibility and on-the-spot crushing. This combination allows for optimized workflow and cost management.

Maintenance Capabilities

Maintenance capabilities and requirements differ significantly between mobile and stationary crushers. Mobile crushers, due to their constant movement and varied operating environments, may require more frequent maintenance checks and repairs. This could include regular inspections for wear and tear, ensuring that the equipment remains operationally efficient. Stationary crushers, while requiring substantial initial setup, benefit from a more stable operating environment. Their maintenance is typically more predictable and less frequent, focusing on routine upkeep and occasional repairs to ensure long-term reliability and performance.

At Al Marwan Machinery, we provide a variety of equipment according to your crushing needs. Take a look at our brand-new inventory and let our experts help you make the right choice!