Desmond Jacobs, AfriSam’s senior engineer for the Western Cape, explains that the replacement crusher is driving operational efficiency while enhancing sustainability and reducing maintenance. The upgrade, part of the company’s long term capital investment strategy, was executed ahead of schedule during the builders’ shutdown from late 2024 to early 2025. AfriSam’s Rheebok Quarry mines a granite deposit to produce aggregate stone, crusher sand, base, sub-base, roadstone and ballast.
“After a thorough selection process evaluating both technical and commercial considerations, the Sandvik CH430 proved to be the best fit for our operational requirements,” says Jacobs. A key factor in the decision was the Sandvik CH430’s footprint which closely matched that of the previous crusher, minimising structural modifications.
“This was a brownfields project, meaning we had to work within existing site constraints,” he explains. “The CH430 fitted seamlessly into our setup, significantly reducing installation time and costs. Time was critical, as we had to install the new crusher during the year-end shutdown.”
Key considerations
He also highlights the importance of safety and efficiency which the Sandvik CH430 delivers through its hydraulic Hydroset system, allowing for precise and automated closed-side setting adjustments.
“Manually adjusting crusher settings can be time consuming, but with this technology we can optimise output with the push of a button,” he says. “This also improves safety as operators do not need to be near the machine.”
For Sandvik Rock Processing, recommending the CH430 for AfriSam was based on careful alignment with the crusher’s expected duty at Rheebok Quarry, explains PC Kruger, business line manager for Crushing Solutions at Sandvik Rock Processing. He says that Sandvik’s 400 Series cone crushers are known for their flexibility and reliability in the quarrying sector.
“The most important aspect of any process design is identifying a solution that meets the client’s needs,” he says. “AfriSam’s Rheebok Quarry produces different product sizes ranging from aggregate stone, crusher sand, roadstone and ballast, so meeting those specifications was imperative.”
To assist in this task, Sandvik Rock Processing specialists used the Sandvik Plant Designer platform which leverages industry data and expertise to strategically plan plant operations. This platform calculates material flow and output levels, assisting in crusher selection and optimisation.
Another key consideration was energy efficiency. While the previous unit operated with a 160-kW motor, the Sandvik CH430 is powered by a 132 kW-unit.
“Reducing power consumption was a critical factor for us,” Jacobs says. “Lower energy demand translates to direct cost savings and supports our sustainability goals in terms of our People, Planet, and Performance commitment.”
Kruger notes that the motor’s maximum power demand was set at 132 kW but the design aimed to stay well below this limit, enhancing energy efficiency while improving crusher output.
Optimising performance
He also explains that the Sandvik CH430 features the Automatic Setting Regulation (ASRi) system, which continuously monitors and optimises crusher performance.
“This advanced feature minimises operator intervention and allows real-time adjustments, improving consistency in product size and quality,” says Kruger. “The system also tracks key parameters like temperature and pressure, enabling proactive maintenance to prevent unexpected breakdowns.”
The new unit enhances product quality by reducing oversized material in the feed stream. Jacobs says that by early 2025, this benefit was already evident with the Sandvik CH430 in operation.
“Our initial assessments showed a dramatic reduction in oversize material being sent for secondary crushing,” Jacobs notes. “This optimises throughput and may allow us to remove redundant processing steps in the future.”
Despite the new unit’s compact size and lighter weight, the AfriSam Rheebok Quarry team was immediately impressed by its performance, throughput and advanced digital features. Predictive maintenance, facilitated by the ASRi system, adds further value.
“We can now digitally monitor crusher liner wear, avoiding significant manual intervention until maintenance is required,” he explains. “This helps us plan maintenance more effectively within the broader quarry operation.”
The Sandvik CH430 cone crusher can be fitted with a variety of mantles and concaves, making it highly versatile. “Operators can choose different mantles and concaves to suit specific processes, using different eccentric throws and bushings,” Kruger explains.
Jacobs adds that the Sandvik CH430’s design allows for better dust control, with more space between the crusher base and the support base to install and maintain dust suppression systems.
Support capabilities
AfriSam also values Sandvik Rock Processing’s strong local presence and support capabilities. “AfriSam has a longstanding relationship with Sandvik Rock Processing, and its Cape Town-based team provides critical support within easy reach of our operations,” Jacobs says. “We also appreciate the local stockholding of spare parts ensuring minimal downtime – a vital aspect of our operations.”
Kruger notes that Sandvik Rock Processing’s Cape Town office offers a range of support services including plant audits to identify opportunities for further efficiency improvements in the crushing circuit.
