Polysius
More flexibility.
More service.
polysius® Impact Crusher More flexibility. More service.
The Polysius PB Impact Crusher combines proven crushing technology with process expertise, application-specific wear solutions and comprehensive lifecycle service – delivering a complete solution for reliable, efficient and sustainable crushing performance
Key figures at a glance
One stage. Straight to your mill.
Where a single-stage crusher is the answer, polysius® comes with the Impact Crusher — a cost-effective, single-step crushing plant that feeds a vertical roller mill or ball mill, built to the highest quality standard in the German polysius® workshop.
Raw materials: Limestone, bauxite, gypsum, slag and overburden.
Compressive strength: < 175 MPa · low moisture · medium SiO₂ content.
Crushing ratio: Up to 60:1 in a single stage.
Capacity: Up to 4,000 tph, depending on product size.
Duty & rotor: Primary, secondary and tertiary crushing; rotor bodies in welded or cast execution, with tailor-made wear parts.
Single-stage impact crushing plant with hydraulically opening housing.
Built from wear parts you can plan for.
The impact crusher shares the same core building blocks for polysius® and third-party machines — engineered so wear parts can be adjusted, turned and replaced with minimum downtime.
Rotor: Cast or welded design for polysius® and third-party machines — shaft, discs, locking assemblies, bearings and blow bars.
Housing & impact liners: Solid design; hydraulic cylinders open the housing for fast, safe access to the crushing chamber. Interchangable bolted liners; Split crusher housing, to provide access to the impact faces and rotor, Hydraulic cylinders open the housing for fast, safe access to the crushing chambe
Impact faces: Impact faces and grinding path are split into three zones — upper, lower and grinding path — adjusted via hydraulic cylinders.
Blow bars: The primary wear part — available in S-shape and rectangular designs and a range of alloys.
Hydraulic system: Opens the housing and adjusts the gap; overload valves protect the wear parts against foreign iron.
Drive Arrangement: V-belts transmit power from the large electric motor of the transmission, arranged on side of the crusher, to the V-belt pulleys mounted on the rotor. The independent drive system provide balanced power transmission to the crusher rotor and ensure stable and reliable operation.
The motor and belt drive is arranged symmetrically to maintain a balanced load distribution and facilitate access for inspection, belt tensioning, and maintenance.Auxiliary Tools: 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. Blow bars changing device – significantly simplifying maintenance work.
Turn it, adjust it, replace it in time.
BLOW BARS & WEAR PARTS
The blow bars do the crushing — and carry the wear. Here's what to watch on each core part, plus how to choose the right alloy, because a worn part quietly costs you tonnes.
The blow bars do the crushing — and carry the wear. Here's what to watch on each core part, plus how to choose the right alloy, because a worn part quietly costs you tonnes.
Blow bars
Fixed by axial safety and hydraulic wedges, blow bars change easily — and a new positioning device makes the exchange safe.
BEST-PRACTICE CHECK
Turn / exchange before the wear volume is used up
Mount opposite bars with similar weights (marked on the rim) to keep the rotor balanced
Protect the crusher from tramp iron (metal detector)
Rotor
Fixed by axial safety and hydraulic wedges, blow bars change easily — and a new positioning device makes the exchange safe.
BEST-PRACTICE CHECK
Turn / exchange before the wear volume is used up
Mount opposite bars with similar weights (marked on the rim) to keep the rotor balanced
Protect the crusher from tramp iron (metal detector)
Impact faces & grinding path
Upper face, lower face and grinding path each take part of the wear — and each sets your product size.
BEST-PRACTICE CHECK
Adjust the gap via the hydraulic cylinders
Watch wear across all three zones
Reset to product size as the faces wear
Housing & impact liners
Hardox liner plates protect the housing; the housing opens hydraulically for access.
BEST-PRACTICE CHECK
Replace worn liner plates in time
Also replace the fixing elements
Use the hydraulic housing opening for safe access
Hydraulic system
The hydraulic system opens the housing, adjusts the gap and — via overload valves — shields the wear parts.
BEST-PRACTICE CHECK
Overload valves protect wear parts against foreign iron
Quick reaction time limits wear in operation
Change product quickly from the control centre
Spart Parts
The right alloy, the right shape, delivered fast — with tailor-made wear-part solutions for polysius® and third-party crushers.
Wear is a process – not just a spare part
The selection of the correct blow bar depends on several parameters, including:
Feed material
Material hardness and abrasiveness
Feed size
Moisture
Impact conditions
Rotor speed
Required product size
Crusher configuration
Operating conditions
Therefore:
One crusher. Different applications. One correct blow bar.
The right wear solution can have a major impact on crusher availability, wear life and total operating cost.
Polysius should position itself as the partner who does not simply supply wear parts, but optimizes the complete wear concept for the individual application.
| Grade | Alloy group | Hardness (HRC) | Performance | Price (1–5) | Shape |
| TKMN (POL-WMC21.13) | Manganese | 30–45 (hardens under load) | 100% | 1 | Both |
| TK520–TK550 | Forged* | 53–56 | 180–200% | 5 | Rectangular |
| POL-WMC58 | Martensitic steel | 54–56 | 140–180% | 3 | Rectangular |
| POL-WMC58RW | Martensitic + MMC | 54–56 (+2000–2500 HV) | 220–250% | 4 | Rectangular |
| POL-WMC72 | Cast chrome | 53–65 | 250–280% | 3 | Both |
| TK-DUR (POL-WMC72RW) | Cast chrome + MMC | 53–65 (+2000–2500 HV) | 400–500% | 4 | Rectangular |
*Forged only available in rectangular shape. Rectangular bars allow more alloy options; the rasp bar weight is marked on the rim. Table for information only.
At the end, the total cost per tonne produced is decisive.
Match the alloy to your material, keep the bars balanced and turn them in time — availability and cost per tonne follow.
A cost-effective alternative to a new crusher.
UPGRADE & REVAMP
Modernise the core parts of almost any impact crusher — ours or a third party's — for lower OPEX at low CAPEX, better performance and a longer life.
Modernise the core parts of almost any impact crusher — ours or a third party's — for lower OPEX at low CAPEX, better performance and a longer life.
Cost & design optimization
A cost-effective alternative to a new crusher investment
Decreasing OPEX at low CAPEX; an upgrade in performance and lifetime
Improved spare-part management by reusing what already exists
Retrofittable to existing crushers and flexible for any application
Available as a tailor-made solution for most impact crushers on the market
Lightweight rotor
Production improvement & easy service
Less power than a cast-rotor design, through reduced rotor weight
Capacity remains even with the lighter rotor
Blow bars fixed by axial safety and hydraulic wedges — changed easily
New positioning device for safe blow-bar exchange; remote service during install
Advanced blow bar design
Longer lifetime through more wear volume
Longer wear-part life and lower investment over the long term
Less shutdown for blow-bar turn or exchange
Rotor retrofittable to existing crushers; flexible for any application
The rectangular shape allows more blow-bar quality options
Product flexibility
Small invest, big effect
Easy, quick product change from the control centre
Optimised spare-part lifetime — quick reaction protects the wear parts
Overload valves shield the wear parts against foreign iron
Small invest, big effect.
Global leading provider of critical process technology and services — more than 160 years of engineering excellence, over 17,600 machines in use, 800+ cement plants and 1,000+ crushers realised worldwide.