Polysius
The crusher for
the toughest applications.
Key Figures
| Max. rotor diameter | Ø 2,200 mm |
| Max. Rotor length | 3000 mm |
| Production capacity | 250-14.000 tph |
| ax. feed size (ROM) | 1,500 mm |
| Max. moisture content | 30 % |
| Crushers realized worldwide | 1,00+ |
Built for extreme material conditions
Where conventional crushing becomes a challenge: The Polysius Double Roll Crusher is particularly suited for applications with demanding material characteristics.
High moisture: Wet and cohesive materials can lead to build-up, blockages and unstable material flow. The Double Roll Crusher is designed to handle high-moisture and sticky materials while maintaining a controlled crushing process.
High abrasiveness: Abrasive materials place significant demands on crushing tools and wear components. The Double Roll Crusher operates at low rotational speed, reducing unnecessary impact and contributing to a controlled wear pattern.
Sticky & cohesive materials: Clay, marl and similar materials can be difficult to process with conventional crushing technologies. The controlled crushing action of the Double Roll Crusher is particularly suited to these challenging materials.
Difficult-to-crush materials: Where material characteristics vary or conventional crushing concepts reach their limits, the Double Roll Crusher provides a robust and controlled alternative.
Main Components
Four components define the DRC platform — each engineered for a long service life and fast intervention when it counts.
Steel rotor body with segmented crushing parts screwed on for easy exchange — inside the crusher, without full disassembly.
Solid and wear-resisting housing, protected by replaceable Hardox liners on both the housing and the rotor side.
Available as direct drive or via v-belts — matched to duty, footprint and maintenance preferences.
Hydraulic or spring-based, depending on raw material and position in the process chain — with overload protection.
Automatic lubration system can be reducing maintenance effort and supporting reliable long-term operation.
Vibration sensors
Product Range – One Platform, Three Duty Classes
Primary, secondary hard or secondary normal – Polysius matches rotor, drive and gap-adjustment concept to your raw material and process position.
DRC – Primary
For primary crushing, Polysius comes with experience.
| Feed material strength | up to 180 MPa |
| Feed size | 0 – 1,500 mm ROM |
| Moisture content | up to 30 % |
| Base frame | Heavy duty |
| Maintenance | In-situ change & weldable crushing segments |
| Protection | Intelligent design with tramp iron protection |
| Raw materials | Limestone, Bauxite, Clay, Gypsum, Marl, sticky / hard / highly abrasive material |
DRC – Secondary Hard
For secondary and tertiary crushing concepts, Polysius comes with the H and N version.
| Feed material strength | up to 180 MPa |
| Feed size | 0 – 400 mm ROM |
| Moisture content | up to 30 % |
| Max. crushing ratio | 1 : 6 |
| Motor power | 55 – 250 kW / each motor |
| Scope of supply | Hydraulic overload protection, variable crushing segment |
| Raw materials | Limestone, Clay, Gypsum, Marl, Recycling, Bauxite, Puzzolana, Shale, Silica, Overburden |
DRC – Secondary Normal
Improved machine design with reduced weight and better access for maintenance.
| Feed material strength | up to 150 MPa |
| Feed size | 0 – 400 mm ROM |
| Moisture content | up to 30 % |
| Max. crushing ratio | 1 : 6 |
| Motor power | 55 – 250 kW / each motor |
| Scope of supply | Hydraulic or spring overload protection, variable crushing segment |
| Raw materials | Limestone, Clay, Gypsum, Marl, Recycling, Bauxite, Puzzolana, Shale, Silica, Overburden |
Double Roll Crusher
| Type | Rotor Dia. [mm] | Rotor Width [mm] | Capacity [tph] | Material |
| DRC08/x-N | 800 | 1000, 1200, 1400 | 200 – 800 | Soft – Medium Hard |
| DRC10/x-N | 1000 | 1000, 1200, 1400, 1600, 1800, 2000 | 240 – 1400 | Soft – Medium Hard |
| DRC12/x-N/H | 1200 | 1000, 1200, 1400, 1600, 1800, 2000 | 400 – 1400 | Soft – Medium Hard – Hard |
| DRC14/x-N/H | 1400 | 1400, 1600, 1800, 2000, 2400 | 400 – 1.600 | Soft – Medium Hard– Hard |
| DRC16/x-H | 1600 | 1400, 1600, 1800 | 400 – 1200 | Soft – Medium Hard– Hard |
| DRC18/x-H | 1800 | 1800, 2000, 2200 | 1000 – 4000 | Soft – Medium Hard– Hard |
| DRC20/x-H | 2000 | (1800), 2000, 2200 | 1000 – 4000 | Soft – Medium Hard– Hard |
| DRC22/x-H | 2200 | (1800), 2000, 2200 | 1000 – 4000 | Soft – Medium Hard– Hard |
Controlled Crushing. Controlled Wear.
High crushing force without unnecessary impact.
The two counter-rotating rolls draw the material into the crushing zone.
Compression and shearing forces break the material down to the required product size.
The low-speed operation provides the required crushing force while avoiding the high circumferential velocities associated with high-speed impact crushers.
This combination makes the Double Roll Crusher particularly attractive for:
High-moisture materials
Sticky materials
Cohesive materials
Abrasive materials
Large feed sizes
Difficult raw materials
Applications requiring low fines generation
Applications where wear cost is a major consideration
Key Benefits
High crushing forces with controlled material reduction.
Reduced wear intensity compared with high-speed impact crushing concepts.
Designed for wet, sticky and cohesive feed materials.
Controlled crushing helps minimize unnecessary over-crushing.
Defined crushing gap for predictable product size.
High torque at low rotational speed for demanding applications.
Robust construction for continuous industrial operation.
Configured around material, capacity and downstream process requirements.
Maintenance & Wear Parts
Crush the material – not your maintenance budget
Controlled crushing with a focus on lifecycle cost
For difficult applications, the purchase price of the crusher is only one part of the equation.
Wear parts, maintenance, downtime and production losses can have a much greater impact on the total cost of ownership.
The Polysius Double Roll Crusher is therefore designed with a focus on:
Low wear: Low-speed crushing and application-specific wear solutions help extend component lifetime.
High availability: obust construction and controlled crushing reduce the risk of unnecessary interruptions.
Predictable maintenance: Wear can be monitored and maintenance activities planned around actual operating conditions.
Long service life: The heavy-duty design is intended for continuous industrial operation.
Liners
Housing liners in best quality — Hardox or similar — protect both the housing and the rotor.
BEST-PRACTICE CHECK
Change the liners inside the crushing chamber in time
Don't reuse screws — always fit a new set of screws and nuts
Tighten to the prescribed torque according to our manual
Rotor
The core part — as basic rotor with crushing segments, or fully equipped with bearing and bearing housing.
BEST-PRACTICE CHECK
Visible check of the grid welding — crosses must be visible
Check rotor vibration regularly
Easy segment change possible inside the crusher
Scraper
Wear-resistant scraper for rotor cleaning — protects the crusher against clogging and improves material intake.
BEST-PRACTICE CHECK
Change the scraper inside the crushing chamber in time
Don't reuse screws — always fit a new set of screws and nuts
Tighten to the prescribed torque according to our manual
Crushing segments
Different plate base materials — manganese cast steel or high-strength cast chrome — with different hard-facing on plate base and tooth.
BEST-PRACTICE CHECK
Replaceable tooth possible — XAR or sinter cast
Match hard-facing to raw material abrasiveness
Inspect tooth wear pattern at each shutdown
Wear Resistance Ladder
The wear resistance of crushing segments directly impacts lifetime and performance — over time, wear widens the crushing gap. Polysius works with various wear materials selected to match your raw material.
- 1 — Hard faced base material
- Entry-level protection for the segment base plate.
- 2 — Welded Hardox tooth
- Reinforced tooth tips for tougher, more abrasive feed.
- 4 — Hard faced teeth
- Maximum lifetime for the most demanding duty.
Raw materials by duty
| Duty | Typical raw materials |
| Primary | Limestone, Bauxite, Clay, Gypsum, Marl, sticky material, hard material, highly abrasive |
| Secondary / tertiary | Limestone, Clay, Gypsum, Marl, Recycling, Bauxite, Puzzolana, Shale, Silica, Overburden |
Ensure the long-term economic operation of your operation.
Revamp & Upgrade – How to Optimize the Machine
Depending on the raw material,Polysiushelps you find the optimum between what is technically possible and economically feasible — from rotor design to drive concept.
Cost and design optimization
Old design: monolithic rotor, worn as a whole unit. Latest design: DRC rotor with exchangeable crushing segments.
More solid & wear resistant design
Quick maintenance and exchange of crushing segments
Several wear solutions available
Can be retrofitted to existing crushers — including third-party rotors
Tailor-made tooth arrangement
Can be offered with technical assistance
Machine optimization levers
| Process modifications | Variable rotor speed via retrofit of a frequency converter improves material intake. |
| GAP adjustment | Operate with hydraulic or spring gap adjustment, depending on duty. |
| Tooth arrangement | Adjusted distribution has a significant impact on capacity and product size. |
| Tooth design | Custom, tailored segments — including ripping teeth — reduce friction wear. |
| Wear resistance | Weld-on Hardox or tungsten carbide tooth brings lifetime to the next level. |
Drive system adaptation: When it comes to sticky, wet and cloggy material, differential roller speed is key to improve material intake and the crushing process. Polysius achieves this mostly by two approaches:
Same pulley diameter for synchronized roller speed
Pulley modification — different pulley sizes result in different, constant rotor speed
The rotor / drive arrangement is easily adjustable to local conditions: drive unit placed on the opposite side, or drive unit placed on the same side.
GAP adjustment: Since DoubleRollCrushers operate with a fixed and a loose roll, the gap can be adjusted via hydraulic system or spring system. A hydraulic system is typically employed for primary crushers, while the more cost-effective spring system is used for secondary / tertiary crushers.
Improved wear resistance: The wear resistance of crushing segments directly impacts the crusher's lifetime and performance. To achieve process optimization, Polysius works with various wear materials that can be selected to match the raw material — from hard faced base material to welded Hardox tooth, stud protection and fully hard faced teeth.
Reference: Double Roll Crusher Integration – Rwanda
At a cement plant in Rwanda, thyssenkrupp Polysius integrated a Double Roll Crusher (DRC) into the existing raw material preparation circuit to improve downstream raw grinding performance.
Due to very limited available space, the crusher had to be installed between the storage system and the raw mill, requiring a compact layout and carefully adapted machine configuration to fit into the existing building structure. The solution was fully integrated without major modifications to the surrounding plant Infrastructure.
The installation of the DRC resulted in a more consistent and suitable feed material for the raw mill.
As a consequence, overall raw mill performance improved, while power consumption was reduced and wear in downstream grinding processes decreased.
Polysius Advantage
The right crusher for the wrong material? No.The selection of crushing technology should start with the material, not with the machine.
Polysius considers:
Moisture
Material hardness
Abrasiveness
Cohesiveness
Feed size
Required product size
Throughput
Downstream process requirements
Expected wear
Your material defines the challenge.
Our engineering defines the solution.