Case Study | GP Company — Premium Wear-Resistant Blow Bar Solution

Client Background
In Poland, GP is a leading aggregate and mining operator supplying materials for infrastructure, road construction, and concrete industries. With multiple medium- and large-scale crushing lines operating under high load, the company requires wear parts with exceptional stability, performance consistency, and extended service life.

Challenges:

The blow bars previously used by GP wore out rapidly when processing high-hardness granite and basalt, resulting in:

• Short service life and frequent downtime

• High risk of chipping or breakage

• Instability in production output

• Increased maintenance and replacement cost
  

Our Solution
1.High-Chromium Alloy Customization (Cr20–Cr26)

  Using high-chromium alloy with secondary aging heat treatment, the blow bars achieved:

• Hardness up to HRC ≥ 60

• Excellent impact and anti-chipping performance

• Stable wear resistance in high-load crushing

2.Reverse Engineering & Structural Optimization

Based on the original samples, we performed reverse engineering and optimized:

• Thickness of high-load zones

• Working surface angles

• Transition radii of mounting areas

Ensuring perfect compatibility with the crusher system and improved ease of installation.

3.DISA Vertical Molding Casting Process

The DISA vertical molding process delivers dense casting quality with minimal defects, followed by CNC grinding and dynamic balancing to ensure smooth and stable operation.

Customer Feedback & Test Results

After three months of operation on GP’s production lines, the results were:

• 40%–55% longer service life depending on material hardness

• More stable crushing efficiency and improved particle shape

• Extended replacement intervals with reduced downtime

• Significant reduction in maintenance costs across multiple lines

GP expressed high satisfaction with the wear performance and operation stability, and a new batch of orders is now under discussion.

Outcome

This collaboration significantly strengthened GP’s crushing performance and operational economics:

• More stable production capacity

• Noticeable cost savings

• Reliable wear part supply

• Improved competitiveness in the local aggregate market