A mid-sized quarry needed more tonnage without adding headcount or downtime. Apache Iron Works answered with a custom mobile crushing plant, and the results speak for themselves: thirty percent more output, lower fuel costs, and a fraction of the old setup time.
The Challenge
A mid-sized quarry faced operational roadblocks:
- Fragmented crushing setup: a mix of aging stationary and portable machines
- Inconsistent output sizes and excess material waste
- Long setup times, up to five days, adding downtime and expense
Rising aggregate demand meant it was time for a smarter, leaner solution.
Apache's Smart Solution
Apache's engineering team designed a mobile plant tailored to the quarry's needs. Key components included:
- Jaw crusher (mobile, trailer-mounted): efficiently handles oversized feed
- Dual-deck vibrating screen: custom slope control for precise sizing
- Integrated grizzly feeder: removes fines before crushing, reducing wear
- Radial stacker conveyors: accelerate stockpiling and cut loader usage
Systems came with intuitive controls to minimize operator training and maximize uptime.
Real Results: Measurable Gains
| Metric | Before | After | Outcome |
|---|---|---|---|
| Output (TPH) | Baseline | +30% | More tonnage per hour |
| Fuel Consumption | Baseline | -18% | Reduced operational cost |
| Setup Time | ~5 days | <36 hours | Faster deployment |
| Operator Hours & Safety | Higher | Decreased | Fewer incidents, less labor |
Why It Worked
- Custom Configuration: Equipment sized for feed material and terrain
- Module Mobility: Trailer-mounted system stays versatile
- Optimized Workflow: Fines removed before crushing, belt-fed screening, all staged for peak efficiency
- Operator-Centric Controls: Simplified training helped reduce human error
Apply This to Your Quarry
This case shows how strategic design boosts production and shrinks operating costs. Ready to replicate these results?
- Learn about our mobile crushing systems
- Check out radial stacker conveyors for faster stockpiling
Frequently Asked Questions
What problems was the quarry facing before the upgrade?
The quarry was running a fragmented mix of aging stationary and portable crushers, producing inconsistent output sizes with excess material waste, and needed up to five days to set up equipment, which added downtime and expense.
What equipment did Apache Iron Works include in the mobile plant?
The plant paired a trailer-mounted jaw crusher for oversized feed with a dual-deck vibrating screen for precise sizing, an integrated grizzly feeder to remove fines before crushing, and radial stacker conveyors to speed up stockpiling.
How much did output improve after the upgrade?
The quarry saw a 30% increase in tonnage per hour, along with an 18% drop in fuel consumption and setup time cut from about five days to under 36 hours.
Why did the custom mobile plant design work so well?
The equipment was sized specifically for the quarry's feed material and terrain, stayed mobile on trailer-mounted modules, and used an optimized workflow with fines removed before crushing, all controlled through operator-centric controls that reduced training time and human error.
Can Apache Iron Works build a similar mobile plant for my quarry?
Yes. Apache Iron Works designs custom mobile crushing systems sized to your specific feed material, terrain, and production goals, the same approach used for this quarry's 30% output increase.
Ready to Boost Your Quarry Output?
If aging equipment or slow setup times are holding back your production, a custom mobile plant built around your material and terrain can help. Request a quote from Apache Iron Works or call 307-772-4563 to talk through your site with our team. You can also visit apacheironworks.com to start building your customized solution.
Apache Iron Works: Engineered to Deliver. Built to Last.
About the Author
Nathan Myers
Co-Founder & Managing Director
Nathan Myers is Co-Founder and Managing Director of Apache Iron Works, headquartered in Cheyenne, Wyoming. With 30 years in the mining and aggregate equipment industry, he has helped design and deliver more than 180 mining projects across 7 states and 7 countries.
