The Complete Guide to Jaw Crusher Plates: Everything You Need to Know

What Are Jaw Crusher Plates?

Definition and Function

• Fixed Jaw Plate: The stationary plate mounted on the crusher frame

• Movable Jaw Plate: The reciprocating plate that moves back and forth

Why Jaw Plates Matter

• Maximize crushing efficiency and throughput

• Reduce replacement frequency and maintenance costs

• Extend overall equipment lifespan

• Minimize downtime and production interruptions

• Improve the quality and consistency of crushed material

Jaw Crusher Plate Materials

High Manganese Steel (Mn13, Mn18, Mn22)

• Excellent abrasion resistance

• Superior work-hardening effect during crushing

• Better impact toughness compared to traditional cast iron

• Self-hardening mechanism that extends service life

• Common grades: Mn13 (10-15% manganese), Mn18 (16-19% manganese), Mn22 (22%+ manganese)

Medium-Alloy Wear-Resistant White Cast Iron

• High hardness levels (typically 190-240 HB)

• Good impact resistance

• Lower cost compared to high manganese steel

• Consistent performance across varied applications

High-Chromium Cast Iron

• Exceptional hardness (≥ HRC 60)

• Excellent wear resistance in highly abrasive conditions

• Better for soft to medium-hard materials

Alloy Steel

Types of Jaw Crusher Plates

By Profile Design

Flat/Smooth Jaw Plates

• Best for: Primary crushing of soft to medium-hard rock

• Characteristics: Smooth surfaces ideal for initial material sizing

• Advantages: Easier to clean, suitable for sticky materials

Toothed or Corrugated Jaw Plates

• Best for: Harder rock and recycling applications

• Characteristics: Teeth or corrugated surfaces increase gripping action

• Advantages: Better material grip, improved crushing action, enhanced reduction ratio

Heavy-Duty Jaw Plates

• Best for: Demanding applications with extreme wear conditions

• Characteristics: Thicker, stronger construction

• Advantages: Extended wear life, reduced replacement frequency

By Manufacturer Standards

• Metso Jaw Plates: Wide range of profiles for various material types

• Sandvik Jaw Plates: Available in multiple series (M1, M2, M7, M8) with different hardness levels

• Kleemann Plates: Designed for European crusher models

• Cone and Jaw Plates by Premier Manufacturers: Custom-engineered solutions

Key Factors Affecting Jaw Plates Selection

1. Material Characteristics

• Select high manganese steel or medium-carbon-low-alloy cast steel

• Higher manganese content (Mn18, Mn22) for extreme hardness

• Consider toothed or corrugated designs for better grip

• Medium manganese steel with self-hardening properties

• Smooth or lightly textured plates

• Lower material cost acceptable

• High-chromium cast iron or custom alloy compositions

• Extreme wear resistance required

• Consider ceramic composite technology for enhanced durability

2. Feed Size and Consistency

• Large Feed Sizes: Require thicker, more robust jaw plates

• Inconsistent Feed: May cause uneven wear; select harder materials

• Pre-Screened Feed: Allows use of lighter-duty plates with potential cost savings

3. Crusher Model and Size

• Correctly dimensioned plates for proper fit

• Appropriate tooth height and pattern

• Compatible mounting systems

4. Operating Conditions

• Impact Load: High impact requires work-hardening materials

• Continuous Operation: Demands higher durability standards

• Intermittent Use: May allow use of standard-grade plates

• Environmental Factors: Corrosive environments may require special alloys

Jaw Crusher Plate Maintenance and Replacement

When to Replace Jaw Plates

• Visible Wear: Tooth height reduced by ≥50% of original height

• Cracks or Deformation: Any visible cracks or permanent deformation

• Edge Chipping: Broken edges affecting crushing surface

• Performance Issues: Uneven output particle size or prolonged crushing time

• Abnormal Vibrations: Unusual vibrations or metallic grinding noises

• Reduced Output: Significant decrease in tons per hour throughput

Replacement Schedule

• Every 6-12 weeks under normal operating conditions

• Replace when tooth height falls below 3/8 inch

• Heavy-duty operations may require more frequent replacement

• Light-duty operations may extend replacement intervals

Weekly Inspection Checklist

1. Visual Inspection:

1. Check for visible wear, cracks, or abnormal wear patterns

2. Measure tooth height and compare to replacement specifications

3. Look for edge chipping or deformation

2. Performance Monitoring:

1. Listen for unusual grinding or metallic noises

2. Monitor for vibrations inconsistent with normal operation

3. Track output quality and quantity

3. Operational Checks:

1. Verify proper jaw plate alignment

2. Check that mounting bolts are secure

3. Confirm toggle plate operation is smooth

Advantages of High-Quality Jaw Crusher Plates

Extended Service Life

• 2-3 times longer service life compared to standard materials

• Work-hardening properties that improve over time

• Better resistance to crack initiation

Cost Efficiency

• Lower cost per ton processed

• Reduced replacement frequency

• Minimized downtime and lost production

• Lower maintenance costs for associated components

Performance Optimization

• Improved crushing efficiency and throughput

• Consistent material output quality

• Better grip and material control

• Enhanced work-hardening effect with repeated use

Reduced Operational Issues

• Fewer unexpected breakdowns

• Less damage to surrounding equipment

• Improved equipment longevity

• Better predictability in maintenance scheduling

Selecting a Reliable Jaw Crusher Plate Manufacturer

What to Look For

1. Material Quality

1. Certified high-grade alloys

2. Rigorous smelting and casting processes

3. Third-party material verification

2. Manufacturing Excellence

1. Advanced heat treatment facilities

2. Precision casting and finishing

3. Quality control at every production stage

4. ISO certifications (ISO 9001, etc.)

3. Technical Capabilities

1. Ability to customize plates for specific crusher models

2. Engineering support for selection

3. Rapid delivery capabilities

4. Company Experience

1. Years of industry experience

2. References from major equipment manufacturers

3. Track record with well-known brands (SANY, Zoomlion, XCMG, Liebherr, etc.)

5. Innovation and Technology

1. Advanced casting techniques (lost foam, DISA molding)

2. Ceramic composite technology integration

3. Continuous product development

Advanced Technologies in Jaw Plate Manufacturing

Ceramic Composite Technology

• Enhanced Hardness: Ceramic particles increase surface hardness

• Extended Lifespan: 2-3 times longer service life compared to standard materials

• Improved Wear Resistance: Greater resistance to abrasive wear

• Cost Savings: 15-25% reduction in total production costs through fewer replacements

Lost Foam Casting Process

• Improved material consistency

• Better dimensional accuracy

• Enhanced internal structure

• Reduced defects and porosity

3D Technology and Design

• 3D modeling and simulation

• Optimized stress distribution

• Faster design-to-production cycle

• Customization for specific applications

Best Practices for Maximizing Jaw Plate Performance

5. Proper Installation

• Ensure correct alignment with crushing chamber

• Securely fasten all mounting bolts

• Use appropriate shims for gap adjustment

• Verify toggle plate operation before operation

6. Operational Practices

• Avoid Overfeeding: Maintain consistent, appropriate feed rates

• Control Feed Size: Pre-screen material if possible

• Monitor Material Hardness: Adjust settings for material type

• Prevent Bridging: Ensure steady material flow

7. Lubrication and Maintenance

• Follow manufacturer's lubrication schedule

• Use appropriate lubricants for your equipment

• Maintain bearings and moving parts

• Keep the crusher clean and free of debris

8. Preventive Maintenance

• Conduct regular inspections per checklist

• Address issues immediately before they escalate

• Keep detailed maintenance records

• Plan replacements in advance

9. Operator Training

• Train operators on proper equipment use

• Educate on early warning signs of wear

• Ensure adherence to operational guidelines

• Promote safety protocols

Conclusion