The cost of setting up a gravel crusher plant (TPH – Tons Per Hour) depends on several factors, including plant capacity, equipment selection, site conditions, and regional labor/material costs. Below is a general breakdown:
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Key Cost Factors for a Gravel Crusher Plant (50-300 TPH)
1. Plant Capacity (TPH)
– Small-scale (50-100 TPH): Lower initial investment
– Medium-scale (150-250 TPH): Balanced cost & efficiency
– Large-scale (300+ TPH): Higher upfront cost but better ROI
2. Equipment Costs
– Primary Crusher (Jaw/Gyratory): $50,000–$500,000+
– Secondary Crusher (Cone/Impact): $60,000–$400,000
– Vibrating Screens: $20,000–$150,000
– Conveyors & Feeders: $10,000–$100,000
– Control System & Electricals: $30,000–$150,000
3. Site Preparation & Civil Work
– Land clearing, foundation work: $20,000–$200,000
– Permits & environmental compliance: $5,000–$50,000
4. Labor & Installation
– Assembly & commissioning: $30,000–$150,000
5. Operating Costs
– Fuel/Power: ~$5–15 per ton crushed
– Maintenance: ~10-20% of initial cost annually
Estimated Total Cost Range
| Plant Capacity (TPH) | Approximate Cost Range |
|———————-|———————–|
| 50-100 TPH | $200,000 – $500,000 |
| 150-250 TPH | $500,000 – $1.2M |
| 300+ TPH | $1M – $3M+ |
Additional Considerations
– Mobile vs. Stationary Plant: Mobile crushers (~15-30% more expensive) offer flexibility but higher per-ton costs.
– Material Hardness: Harder rocks require more robust (expensive) crushers.
– Location: Remote sites increase logistics costs.
– Automation: Higher upfront cost but reduces long-term labor expenses.
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