In industries such as open-pit mining, coal, metallurgy, and building materials, the continuous, efficient, and stable crushing of large pieces of materials has always been a core pain point in the production process. Traditional crushing systems have a fragmented process, numerous equipment combinations, high construction costs, and poor adaptability to harsh working conditions, making it difficult to meet the requirements of modern continuous operations. The emergence of the Feeder Breaker has effectively solved the aforementioned industry problems and has become the mainstream equipment for crushing heavy and large pieces of materials.
What Is A Feeder Breaker?
A feeder breaker is a heavy-duty continuous crushing equipment that integrates functions of feeding, screening, crushing, and conveying.
It is mainly used in material bins with certain pressure and below the hoppers, for short-distance, uniform, and continuous crushing, screening, and transportation of various materials with high bulk density.
It can complete heavy work in harsh environments and has strong adaptability to changes in material particle size composition, temperature, viscosity, frost, rain, snow, and even frozen materials. It ensures uniform and accurate feeding. This machine can be installed horizontally or at an angle, and the maximum upward inclination angle is 15°.
At the same time, the feeder breaker integrates the functions of material transportation and crushing, achieving the completion of raw feeding, crushing, and discharging on the same horizontal plane, forming a heavy-duty continuous crushing system for continuous horizontal material flow crushing.
Unlike traditional single-machine combined crushing systems, it is a key equipment for efficient crushing in the mining and coal industry.
EXCT Feeder Breaker Technology Advantages
At the end of the last century, Xinjiang Teda Electric Power Tianchi Energy Open-pit Mine was the first to introduce a well-known foreign brand feeder breaker, marking the beginning of its application in China. However, during actual use, various problems such as insufficient technical support, high maintenance costs, expensive spare parts with long lead times, and inconvenient replacement were gradually exposed. At the same time, other owners also faced similar problems.
To address these challenges, our company collaborated with China University of Mining and Technology to successfully develop the first Feeder Breaker in China and successfully achieved stable operation at Tianchi Energy Open-pit Mine, completing the domestication of imported equipment and filling the domestic gap.
By the end of 2025, this equipment has been implemented in over 80 projects, with a domestic market share exceeding 90%, and has been exported to multiple countries and regions such as Mongolia, Kazakhstan, Indonesia, and Russia.
Feeder Breaker Working Principle
The feeder breaker consists of a chain conveyor and a crushing unit, achieving the combination of feeding and crushing functions.
The materials are directly unloaded from the dump truck into the silo, or they are unloaded into the silo by the bulldozer or loader.
When the feeding device drive mechanism starts to operate, the drive sprocket drives the chain to move horizontally within the conveying box, and at the same time, the material is pulled forward.
When the chain and the materials pass through the rotating toothed rollers in the crushing box, since the large materials cannot pass through the specific space between the toothed rollers and the bottom plate, the large materials will be impacted, squeezed and stretched by the rotating toothed rollers until they are crushed into small materials that can pass through.
Feeder Breaker Structure
The feeder breaker is composed of four core units, ensuring the stable operation of the equipment and the effectiveness of the work:
►Conveying Unit
As the main component of the equipment, it is responsible for material loading and continuous conveying, providing stable driving force for the movement of materials, and is suitable for heavy-load and high-flow conveying requirements.
►Screening Unit
It is divided into two modes: static pre-screening and dynamic pre-screening. These can be selected based on the characteristics of the materials, effectively separating fine particles, avoiding unnecessary crushing, and reducing energy consumption and wear.
►Crushing Unit
The core working component consists of crushing tooth roller, drive device and crushing box. It is equipped with high-strength and wear-resistant tooth rollers, which can withstand high impact loads and has high crushing efficiency.
►Intelligent Protection Unit
Equipped with functions such as stall protection, chain break protection, overload protection, three-phase current imbalance detection, and automatic material flow adjustment, it enhances the operational safety of the equipment.
Feeder Breaker Advantages
The feeder breaker, with its integrated design and heavy-load technology, possesses multiple competitive advantages in the industry:
01/ Large Crushing Size
The maximum feed particle size can reach 2500mm, perfectly solving the industry problem of difficult crushing of large-sized materials in open-pit mines and coal mines.
02/ Screening Followed By Crushing
The "pre-screening" process directly separates out the qualified fine materials, reducing excessive crushing and maximizing the yield of the open-pit mine block coal, thereby enhancing the economic benefits and value of the mining company.
03/ Integrated Integration
This machine integrates conveying, screening and crushing functions into one unit. The process is simple, the equipment investment cost is low, and the on-site construction period is short.
04/ Modular Design
The modular combination design is adopted, which can be flexibly configured according to production capacity, site conditions, and material characteristics to meet the customized needs of different customers.
05/ High Level Of Intelligence
It features stall protection, chain break protection, three-phase current imbalance detection, and automatic adjustment of material flow.
06/ Strong Adaptability To Working Conditions
It can withstand harsh environments such as frost, rain, snow, high humidity, and frozen materials, and can operate continuously and stably without interruption.
07/ Low-Carbon And Energy-Saving
The overall installed power of the machine is low, with lower energy consumption and lower carbon emissions. This is in line with the current trend of environmental protection.
The feeder breaker is an integrated, heavy-load, and continuous-generation new generation of crushing equipment, which has completely changed the complex process, low efficiency and high cost situation of the traditional crushing system.
With advantages such as large feed particle size, screening before crushing, intelligent safety, and strong adaptability, it has become the core crushing equipment for open-pit coal mines, mining, metallurgy and other industries.
If you have any questions about the selection, application, or technical parameters of the Feeder Breaker, or if you need to customize a dedicated crushing solution based on your specific working conditions (such as open-pit mines, metallurgical mines, etc.), please feel free to contact us at any time.
We have a professional technical team that can provide one-on-one consulting services, precisely matching the equipment models and answering questions related to equipment operation and maintenance, helping you reduce investment costs and improve crushing efficiency.
