Crusher & Aggregates
You know what you blasted. You know what you sold. The gap is the business.
You know what you blasted and you know what you sold. The gap is the business. Between the face and the weighbridge sit excavation, hauling, crushing, screening and stockpiles, and every one of them loses material nobody accounts for.
Operational areas
- Production
- Stock
- Weighbridge
- Royalty
- Sales
- Machinery
Built for this
Crusher Management System
Production, yield, stock, royalty and dispatch
One afternoon
The blast yields what it yields. Somebody writes a number in a register. Tippers run all day, the crusher runs all day, the weighbridge prints tickets all day. At the end of the month the stock standing in the yard does not match the stock on paper. The difference gets written off as handling loss, because there is no other word available for it.
Crusher, Quarry & Aggregates businesses manage a constant flow of
- Blasts
- Excavators
- Tippers
- Crusher hours
- Screens
- Stockpiles
- Weighbridge slips
- Royalty passes
- Wear parts
- Power & diesel
The operation
How the business runs — and where it stops being visible
Every stage produces information. The problem is rarely any single stage; it is that they never meet. The marked stages are where the record either stops, or stops being trusted.
Drilling & blasting
Excavation
Hauling
Material moved from face to crusher is counted by trip, not by tonne
Crushing
Yield per blast stays unknown, so nobody can say what the plant converted
Screening
Stockpile
Physical stock and book stock diverge, and the difference is only found at year end
Weighbridge
Royalty pass
Dispatch
Sale
Where it breaks
The problems that cost real money
Not the ones a brochure lists. The ones that come up when you sit with the person doing the work.
Actual yield never matches theoretical, and nobody computes the gap
Blasted tonnage against saleable output, split by product size, is the core number of a quarry. It requires three registers to agree, so almost nobody produces it.
Stockpile figures are estimates wearing the clothes of numbers
Closing stock of 20mm, 10mm, GSB, M-sand and dust, measured by looking at the pile. The register and the yard drift apart all year and meet once, at audit.
Royalty and transit pass reconciliation happens under deadline
Passes issued against material dispatched, against permitted quantity. A mismatch is a compliance problem, and it gets checked in a spreadsheet the night before it is due.
Cost per tonne by product is unknown
Units consumed by the crusher, diesel burnt by excavators and tippers, tonnes produced. Nobody divides one by the other, so nobody knows whether the 10mm or the dust is carrying the plant.
Wear parts are replaced by memory
Jaw plates, cone liners and screen mesh have a predictable life measured in tonnes. Tracked in someone's head instead, they fail on the busiest day of the month.
What changes
What the system changes
The weighbridge ticket and the royalty pass become the control points. Production, stock movement, dispatch and compliance all flow from the same record. Yield, stock and cost per tonne stop being reconstructions and become daily figures.
The product
Built for this industry: Crusher Management System
Crusher Management System tracks production, stock, machinery, royalty compliance and dispatch across the quarry, so yield, cost per tonne and closing stock are numbers you can defend.
Production
Blast records, excavated quantity, shift-wise crusher output by product size, actual vs theoretical yield
Products & stock
20mm, 10mm, 6mm, GSB, WMM, M-sand, P-sand and dust. Stockpile movement, opening and closing stock, variance
Weighbridge
Tare and gross capture, ticket generation, vehicle-wise dispatch, integration with existing weighbridge hardware
Royalty & compliance
Mineral permit and lease quantity, transit and royalty pass issue, dispatched vs permitted reconciliation
Machinery
Excavators, tippers, crushers and screens. Running hours, breakdown log, downtime and its cost in lost tonnes
Wear parts
Jaw plate, cone liner and screen mesh life in tonnes, replacement history, consumption cost per tonne
Custom & enterprise
When the product isn't the whole answer
Groups running several leases, crusher plus RMC plus transport under one owner, or statutory reporting a state handles its own way. That is enterprise work, and it starts from the product rather than from nothing.
Our approach
However it gets built, it starts the same way
We spend time in the operation before proposing anything. The first three stages finish before a single screen is designed.
Understand
How the business actually works
Analyse
Where time, money and clarity are lost
Research
What the better way forward looks like
Design
Workflows, data and interfaces
Build
Modern, maintainable technology
Evolve
Improve as the business changes
Let's understand your operation.
Tell us how the business runs today and where it becomes difficult. We'll start there.