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Industrial secondary cone crusher processing crushed rock in a mining operation.

Reduced oil change costs on secondary cone crusher

Frequent service shutdowns caused by contaminated gear oil led to high operating costs on a secondary cone crusher. Installing a CJC® Oil Filter significantly reduced oil changes, pump failures, and maintenance costs.


Application Snapshot

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Industry:

Mining

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Country:

United States

Oil droplet icon representing oil type or lubrication fluid.
Oil type:

Gear oil, ISO VG 150

Executive summary

A secondary cone crusher at a copper mine in the United States experienced expensive monthly service shutdowns. Frequent system pump breakdowns were caused by contaminated gear oil, resulting in high costs for oil changes and spare parts.


A CJC® Oil Filter with a dirt holding capacity of 16 kg was installed on the gear oil system to continuously remove contamination.

Following installation, major savings were achieved on oil changes and gear pumps. The payback period was less than one month, and after the initial testing phase, CJC® Filters were installed on all 14 crushers at the site.

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Contaminated gear oil controlled

The CJC® Filter continuously removes contamination, stabilising gear oil condition in harsh mining environments.

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Substantial annual maintenance savings

Annual costs per crusher were reduced from USD 76,900 to USD 5,260, delivering savings of USD 71,640.

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Fewer pump failures and shutdowns

Gear pump breakdowns were significantly reduced, eliminating frequent unplanned shutdowns.

Leaf icon representing lower oil consumption and reduced waste oil generation.

Lower oil consumption and waste oil handling

Reduced oil changes significantly lowered oil consumption and waste oil generation.

Engineers inspecting an oil filtration system in an industrial mining environment.

Client brief

The customer operates a copper mine in the United States using secondary cone crushers for mineral processing. The site operates 14 crushers under heavy contamination conditions.

Two gear oil samples showing contaminated oil and cleaner oil for comparison.

Challenge

Frequent contamination of the gear oil caused monthly service shutdowns and system pump breakdowns. Oil changes and spare part replacements resulted in high annual maintenance costs per crusher.

CJC® Oil Filter installed on a crusher gear oil lubrication system in a mining plant.

Solution

A CJC® Oil Filter HDU 27/108 was installed on the gear oil system to continuously remove contamination and protect the gear pumps.

Mobile secondary cone crusher processing rock in a mining quarry.

Controlling contamination in secondary cone crusher gear oil

Before filtration, the site experienced monthly service shutdowns due to contaminated oil. Annual costs for oil changes alone reached USD 60,000 per crusher, with additional costs for gear pump replacements.


After installation of the CJC® Oil Filter, oil condition stabilised and contamination was effectively controlled. Oil change costs were reduced to USD 5,000 annually, and gear pump costs were reduced from USD 16,900 to USD 260 per year.

Measurable results and operational impact

Total annual maintenance costs per crusher were reduced by 92–98%, delivering annual savings of USD 71,640 per crusher.


Following the successful trial, CJC® Filters were installed on all 14 crushers at the site, resulting in potential total annual savings of USD 1,002,960 across the operation.

CJC® Oil Filter installed on a secondary cone crusher gear oil lubrication system.

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