9 Causes & Solutions to Easily Fix Impact Crusher Blockage

2025-10-14 Visits:

9 Causes and Solutions to Easily Resolve Impact Crusher Material Blockage!

Material blockage is one of the most common failures in impact crusher operation. During production, once a blockage occurs, it forces the equipment to shut down, wastes significant time clearing accumulated material, and impacts the efficiency of the entire production line. So, what are the specific causes of impact crusher blockage, and how should it be handled? We will share the reasons and solutions for material blockage in impact crushers.

  1. High Material Moisture, Prone to Clogging
    If the raw material has high water content and great viscosity, the crushed material easily adheres to the screen meshes and both sides of the liner plates. This reduces the crushing chamber volume, lowers the screen passage rate, and causes material blockage.
    Solution: Pre-heat the impact plates and feed chute, install drying equipment, or sun-dry the material to reduce its moisture content.

  2. Excessive or Too Rapid Feeding
    When the feed into the impact crusher is excessive or too fast, and it cannot be crushed and discharged in time, blockage will occur.
    Solution: During feeding, pay attention to the ammeter needle deflection. A large feed will cause a high ammeter reading. Exceeding the machine's rated current leads to overload operation. Prolonged operation under these conditions can cause blockages and even burn out the motor. When this happens, immediately reduce the feed rate by adjusting the feeding equipment.

  3. Discharge Speed Too Slow
    Under normal conditions, the feed rate and discharge rate are balanced. Excessive or rapid feeding causes blockages, and an overly slow discharge rate also leads to material accumulation inside the machine, resulting in a blockage and preventing normal operation.
    Solution: Avoid machine overload; adjust the feed rate according to the machine's processing capacity. During production, adjust the discharge outlet size promptly based on the actual situation to ensure smooth discharge of crushed material. If the material being crushed changes, adjust the discharge outlet accordingly.

  4. Material Too Hard, Too Much, or Oversized
    When the material is very hard and difficult to crush, or the feed size exceeds the crusher's maximum limit, insufficient crushing between the impact plate and hammer can block the discharge outlet.
    Solution: Before material enters the crushing chamber, confirm the crusher's suitable material types, especially regarding material properties, to ensure correct feeding. Avoid overloading the crushing chamber; an electric bell and warning light can be installed at the feed port to control input. Pre-crush large pieces before feeding them into the chamber to meet or approach crushing requirements and prevent blockages.

  5. Worn Equipment Parts
    If key components of the impact crusher are worn (e.g., hammers, impact plates), poor crushing efficiency can also cause blockages.
    Solution: Regularly check parts for wear and replace severely worn components promptly to ensure effective crushing and reduce blockages.

  6. Loose V-belts, Insufficient Power Transmission
    The crusher relies on V-belts to transfer power to the wheel for crushing. Loose V-belts cannot effectively drive the wheel, impacting crushing performance or preventing crushed material from being discharged, leading to blockages.
    Solution: During operation, regularly check V-belt tension and adjust it promptly if necessary.

  7. Damaged Impact Crusher Main Shaft
    The main shaft is the "lifeline" for the proper operation of all crusher components. A damaged main shaft affects all parts, preventing normal operation, halting the equipment, and causing blockages.
    Solution: Operators and maintenance personnel must prioritize main shaft maintenance: ensure timely lubrication, perform regular upkeep, and address issues immediately to avoid impacting production.

  8. Improper Operation
    Some blockages are caused by operator error, potentially due to unfamiliarity with the process or momentary mistakes.
    Solution: Equipment operators should undergo rigorous training and be certified before operating. They must be familiar with both the equipment's operating procedures and the entire production line process.

  9. Poor Crushing Chamber Design
    The crushing chamber is where material processing primarily occurs, with discharge from the bottom. Poor design can easily cause material to block at the chamber's lower part.
    Solution: Improve the crushing chamber by adopting a curved design where the nip angle gradually decreases from top to bottom. This design helps larger crushed pieces descend and allows finer material to discharge freely from the crushing zone, facilitating smooth material flow and reducing blockages. To avoid issues from poor design, it's best to purchase machines from reputable, major manufacturers.

When a blockage occurs in your impact crusher, don't rush into blind repairs. First, identify the root cause, then take targeted, reasonable measures to solve the problem and minimize the negative impact of the blockage. If you have questions or suggestions, please leave a comment.


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