How to Choose the Right Crusher: Jaw, Impact, or Cone?

Do you know what determines efficient operation at quarries, construction sites, or recycling yards? The right choice of crusher! Yet many face the same dilemma – which crusher should you choose? Each has its own advantages and disadvantages, so it’s important to pick the one that best meets your needs.

In this article, we’ll briefly and clearly explain the differences between jaw, impact, and cone crushers, their applications, what “reduction ratio” means, and the main pros and cons – so your decision is easier and more beneficial.

Three Main Types of Crushers
All crushers perform the same basic function – reducing material size – but their working principles and applications are very different.

• Jaw Crusher

• Impact Crusher

• Cone Crusher

Let’s take a closer look at each option:

1. Jaw Crusher – The Classic Choice for Primary Crushing

When to choose it?
A jaw crusher is ideal for the primary crushing of large and hard materials, such as stones, large concrete blocks, or major demolition debris.

How does it work?
The principle is simple – two crushing plates (“jaws”, one moving, one fixed) compress the material, breaking it into smaller pieces.

Reduction ratio:
With a jaw crusher, you can typically reduce the input material size by 3–5 times in one pass.

Pros:

• Extremely reliable and robust, even with the toughest materials

• Perfect for large rocks or concrete blocks

• Long wear-part lifespan

Cons:

• Final fraction is often irregular, angular, and lacking in “cubical” shape

• Not suitable for producing very fine fractions

• Can be noisy

Model examples:
Mobile Keestrack B3h and B4he – great for recycling yards, while B5he and B7he are true workhorses for quarries.

2. Impact Crusher – Versatility and Maximum Cubicality

When to choose it?
If the most important factors are high-quality, cubical aggregate shape and surface area, and versatility, the impact crusher is your best choice. It is suitable for secondary crushing and for materials that are not extremely hard: asphalt, concrete, limestone, dolomite, or construction waste.

How does it work?
Material is not compressed but rather thrown at high speed against metal plates, resulting in better crushing efficiency and a superior final fraction shape.

Reduction ratio:
An impact crusher usually reduces material by 7–10 times in a single pass!

Pros:

• Produces regular, cubical aggregate

• Especially suitable for processing construction waste

• High productivity and versatility

• Settings can be easily adjusted as needed

Cons:

• Produces a lot of fine fraction (which isn’t always required)

• Impact parts wear out faster, so maintenance costs may be higher

Models:
Keestrack R3e – compact and agile, while the R5he and R6he models can process up to 520 t/h.

3. Cone Crusher – Precision for Fine Fractions

When to choose it?
If you already have a primary crushed product and want to obtain finer fractions, the cone crusher is irreplaceable. Popular in quarries, especially for hard rock, where a large amount of fine aggregate or chips is needed.

How does it work?
Material is compressed between a moving cone and a fixed shell. While cone crushers can’t handle very large fragments, the output is precise and consistent.

Reduction ratio:
Cone crushers, like jaw crushers, typically reduce material by 3–5 times per pass.

Pros:

• Produces very consistent, precise-sized fractions

• Durable – excellent with abrasive materials

• Perfect for secondary/tertiary crushing

Cons:

• Cannot accept very large pieces

• Requires more frequent adjustments to match output needs

• Can sometimes produce excessive flat particles

Models:
Keestrack H4e, H6e, and H7e ZERO – a wide selection for different requirements.

For more about jaw, impact, and cone crushers, see the official Keestrack website or FLSmidth crushers.

Crusher Selection – It’s Not Just About Price

When choosing a crusher, it’s worth considering not only the initial purchase price, but also the total operating costs. Modern crushers, especially those with hybrid or electric drives, significantly reduce fuel consumption and help save money long-term.

Why choose advanced equipment?

• Lower fuel costs: Hybrid drives, such as Keestrack ZERO, ensure lower CO₂ emissions and cheaper operation.

• Easier maintenance: Automatic lubrication systems and easy access to key components save time and money.

• Primary prescreening: The prescreen function extends the lifespan of key components and reduces repair frequency.

How to Choose a Crusher – In Short

Ask yourself these questions:

1. What is your material?

   • Boulders, primary crushing (concrete, rock)? – Jaw crusher.

   • Dolomite, limestone, smaller construction debris, or milled asphalt? – Impact crusher.

   • Secondary/tertiary crushing, fine gravel, highly abrasive material? – Cone crusher.

2. What is your goal?

   • Just to reduce the size of large fragments? – Jaw crusher.

   • To get high-quality, cubical aggregate? – Impact crusher.

   • To produce a lot of precise, fine fractions? – Cone crusher.

The right crusher is the shortest path to efficient work, lower costs, and a quality result.