Polysius
More flexibility.
More service.
polysius® Hammer crusher More flexibility. More service.
Single-shaft mammut® and double-shaft titan® — one-step crushing to feed your VRM or ball mill, and backed by the wear-part and revamp programme that keeps them running beyond decades. Today's hammer crushers are the result of decades of development, combining the best features from leading brands like Claes, O&K, Hischmann, Krupp, Bühler-Miag and Thyssenkrupp Fördertechnik to form the advanced Polysius crushing technology we use today.
Key figures at a glance
- 80+ Years. One Crushing Heritage.
- decades of experience in heavy-duty crushing technology
- 170+ MAMMUT™ Crushers
- proven in some of the most demanding high-capacity applications worldwide
- 400+ TITAN™ Hammer Crushers
- a large installed base and extensive field experience
- Proven for decades – not just years
- technology with a track record that speaks for itself
- Up to 25 mm in one crushing stage
- outstanding reduction performance from a single machine
- Built for Heavy Duty
- robust machines engineered for demanding materials and continuous operation
- Built to Last
- long service life, high availability and proven reliability
- Experience that goes beyond the machine
- application know-how, optimization and lifecycle support
Different Crushers for different Requirements
One stage. High reduction. Defined product. Engineered for maximum crushing performance, this machine delivers precisely controlled product sizing even when working with the most challenging materials. Its robust design ensures high performance under demanding conditions, while thoughtful engineering guarantees long-term reliability you can count on.
| mammut® | titan® | |
| Type | Single-shaft hammer crusher | Double-shaft hammer crusher |
| Raw materials | Limestone, marl, gypsum, chalk | Limestone, marl, gypsum, chalk, mixed |
| Max. raw material moisture | 8% | 20 % |
| Compressive strength | < 150 MPa | < 200 MPa |
| Crushing ratio | up to 80:1 | up to 100:1 |
| Capacity | 400 tph up to 2,000 tph | 400tph up to 3,000 tph* |
| Installed base | up to 170 units | up to 400 units |
| Also | Lifetime beyond decades | Over 10 third-party refurbishments |
*Depending on product size. Both are made to the highest quality standard , with tailor-made wear-part solutions.
Built from wear parts you can plan for.
Every hammer crusher shares the same core building blocks — engineered so that the parts exposed to wear can be inspected, turned and replaced with minimum downtime.
Weldable steel discs shrunk on a squared (or pentagon) shaft; hammers, axles and bearings can be pre-assembled.
Forged, cast, mmc/ceramic hammers or bimetal execution — matched to your raw material.
Limits the final grain size; two-piece design in extreme wear-resistant steel with quick-change segments. Optional with grate bar adjustment system
Sits between the two rotors as a core wear part — manganese cast steel with hard-facing.
Extreme wear-resistant steel liners protect the housing and rotor end discs.
High-alloy stainless axles with an extraction thread; roller bearings in cast or welded housings.
V-belts transmit power from the large electric motors of the transmission, arranged on both sides of the crusher, to the V-belt pulleys mounted on each rotor. The two independent drive systems provide balanced power transmission to the crusher rotors and ensure stable and reliable operation.
The motors and belt drives are arranged symmetrically to maintain a balanced load distribution and facilitate access for inspection, belt tensioning, and maintenance.
The crusher is equipped with dedicated auxiliary tools to facilitate safe and efficient maintenance:
Rotor turning device – for controlled and safe rotor positioning during maintenance.
Hydraulic extraction device – for easy removal of crusher components, including the necessary hydraulic equipment.
Rotor grate basket trolley – enables both grate baskets to be safely withdrawn from the crusher during maintenance.
Hammer extraction device – significantly simplifying maintenance work.
Automatic lubration system can be reducing maintenance effort and supporting reliable long-term operation.
Vibration sensors
Bring an ageing crusher back to life.
Ours or a third party's — modernise the core parts, cut OPEX at low CAPEX, and invest for the next decade.
Cost & design optimization
Redesigned mammut® rotor in extreme wear-resistant steel
More solid, more wear-resistant design at a more attractive market price
Quicker delivery than the older execution; can be retrofitted to existing crushers
HighTemp versions for process temperatures up to 350 °C
Decreases OPEX — and can be offered with technical assistance
Improved fly wheel
Conversion from ELSI slip clutch to elastic clutch
Up to 50% less investment than an ELSI coupling
Easy installation with a tension set — no further adjustment
One retrofit package; quicker delivery and lower OPEX
Available for Krupp MIAG, DHB and HAPRA designs
Extraction tools
Hammer & hammer-axle extraction tools for all titan® crushers
Reduce maintenance time with quick, safe hammer exchange
Better access via a temporary extraction device
New hammers with a lifting eye; lifting beam and clamp included
Reuses the grate-basket-carrier hydraulic aggregate
Crusher update
From an obsolete crusher — ours or a third party's — to a Polysius core
Tailor-made rotor improvements with high wear-resistant solutions
Bring obsolete crushers back to life by changing the core part
Capacity increases while remaining the existing drive unit
Local sourcing of steel parts, remote service support — Polysius focuses on the core
Invest for the next decade.
Turn it, check it, replace it in time.
Hammer crushers reward attention. Here's what wears, what to watch, and the best-practice check for each core part — because a worn part quietly costs you tonnes.
Hammers — turning
Turn the hammers in good time (first side ≈60% of the service life, second side ≈40%). Turning too late drives friction wear into the rotor and grate baskets.
BEST-PRACTICE CHECK
Turn hammers before the edge rounds off
Max. hammer-eye ovality 5 mm
Protect the crusher from tramp iron (metal detector)
Rotor
The rotor is the heart of the crusher — available as a basic rotor or partly/fully equipped with bearings, axles and hammers.
BEST-PRACTICE CHECK
Visual check of the grid welding — crosses must stay visible
Check rotor vibration
Keep steel-bushing ovality within 3 mm
Anvil (only at titan®)
A core crushing part exposed to extreme wear. Grid welding both extends life and enables visual inspection of anvil and rotors.
BEST-PRACTICE CHECK
Reweld regularly — it is mandatory
Replace from time to time
A worn anvil shortens grate, hammer and rotor-disc life
Grate basket
The two-piece basket lets you swap segments quickly for summer/winter operation on a durable base frame — at lower maintenance cost.
BEST-PRACTICE CHECK
Quick segment change via quick-release axles
Insert a progressive grate if the basket clogs
Widen gaps toward discharge (e.g. 70 → 120 mm)
Housing liners
Cast steel for the impact wall, Hardox (or similar) for the housing liners — changed inside the crushing chamber before they wear through.
BEST-PRACTICE CHECK
Change liners in time
Never reuse screws — fit new screws & nuts
Tighten to the prescribed torque; replace fixing elements too
Hammer axles
Made of high-alloy stainless steel, with an internal thread on one end as the extraction point.
BEST-PRACTICE CHECK
Monitor and check once a year
Keep diameter reduction within 5 mm
Beyond that: burrs and problems pulling the axle
What worn hammers cost you
| Product size after the crusher | Coarser |
| Throughput capacity (t/h) | Reduced |
| Size-reduction ratio | Reduced |
| Power consumption (motor kW) | Slightly higher |
| Maintenance & downtime | Increased |
The right alloy for your grain size and abrasiveness.
A correct hammer selection drives lifetime, maintenance intervals and availability. Wear resistance rises from manganese through to Cr-cast steel with a carbide inlay.
Manganese: Ductile base, self-hardening in the impact area – needs a high impact load.
Forged: Extremely hard, solid protection against abrasion.
Rolled steel (only for Mammut crusher): Balanced wear and impact resistance, with a price advantage.
Cr-cast + inlay: Ultra wear-resistant ceramic particles for the longest life, ductile base.
Increasing wear resistance
| Grade | Material | Performance | |
| TK-GSMN | Manganese steel | 100% | |
| TK-50 | Rolled steel | 150–200% | |
| WMC60 NEW | Cast steel | 150–200% | |
| TK-520 | Forged steel | 150–200% | |
| TK-DUR-C | Cr-cast steel with titanium-carbide inlay | 250–400% |
Cast steel (WMC60) is comparable to forged hammers, with a more attractive price and quicker delivery.
At the end, the total cost per tonne produced is decisive.
Turn hammers in time, keep the anvil welded, and match the alloy to your material — availability and cost per tonne follow.
Reference: Doubling Crushing Capacity at Salonit Anhovo (Slovenia)
At the Salonit Anhovo plant, a targeted crushing modernization removed a critical bottleneck in primary crushing and improved downstream raw grinding efficiency.
Our audit revealed that the existing primary crusher (HBK 25120) produced an overly coarse product (< 70 mm), limiting raw mill performance – while the quarry material was hard, abrasive and sticky, especially during winter. To avoid high project costs and complex permitting, thyssenkrupp Polysius integrated a new double shaft hammer crusher system directly into the existing crusher building.
This approach resulted in significant CAPEX savings, as extensive civil works were avoided and no complex or time-consuming permitting procedures were required. The modernization doubled crushing capacity from 500 t/h to 1,000 t/h and reduced product size to <30 mm, creating a stable and efficient feed for the raw grinding process and enabling a rapid conversion to a state-of-the-art crushing solution within a very short implementation timeframe.
Project Impact
+100% crushing capacity (500 → 1,000 t/h)
Product size reduced to < 30 mm (from < 70 mm)
Improved raw mill efficiency through finer feed material
Optimized for sticky material conditions, ensuring reliable operation
Significant CAPEX cost reduction
No complex permitting procedures required