Located in the heart of southern Germany, a medium-sized quarry with over 30 years of operation faced a critical crossroads in 2024. Specializing in limestone crushing for construction aggregates—used primarily in local road construction and concrete production—the quarry had been relying on an outdated jaw crusher for its primary crushing stage. As demand for high-quality, uniformly sized aggregates surged with the region’s infrastructure expansion plan, the old equipment struggled to keep pace, leading to costly bottlenecks, frequent breakdowns, and rising operational expenses that threatened the business’s competitiveness.
“Our old crusher was a constant headache,” recalls Markus Weber, the quarry’s operations manager. “It could only handle a maximum feed size of 800mm, which meant we had to pre-crush large limestone blocks manually—a time-consuming and labor-intensive process. Worse, its hourly capacity rarely exceeded 200 tons, and it broke down at least once a week, forcing us to halt production for hours, sometimes even days. The maintenance costs were spiraling, and we couldn’t meet the tight delivery deadlines our clients were demanding. We knew we needed a replacement that could deliver more power, better efficiency, and greater reliability.”
After an extensive evaluation of jaw crushers from leading manufacturers, the quarry’s management team selected the C150 Jaw Crusher—drawn to its robust design, impressive performance parameters, and proven track record in similar aggregate production scenarios. The C150, engineered for heavy-duty primary crushing, boasts a feed opening of 1500×1200mm, allowing it to handle large limestone blocks up to 1200mm without pre-crushing, and a maximum hourly capacity of 500 tons—more than double the output of their old equipment. Its deep, non-dead-zone crushing chamber, optimized for efficient material flow, and wear-resistant manganese steel jaw plates were additional selling points, promising reduced downtime and lower maintenance costs.
The installation and commissioning of the C150 were completed in just 10 days—a streamlined process that minimized production disruption, thanks to the crusher’s modular design and the manufacturer’s on-site technical support team. From the first day it went online, the C150 delivered transformative results. “The difference was night and day,” says Weber. “We eliminated the need for manual pre-crushing entirely, which cut our labor costs by 25%. The crusher runs smoothly for 16 hours a day, six days a week, with only routine maintenance required—we’ve had zero unplanned downtime in the first six months, which is unheard of for us.”
Beyond efficiency and reliability, the C150 also elevated the quality of the quarry’s end products. Its adjustable discharge opening—ranging from 80mm to 200mm—allowed the team to precisely control the particle size of the crushed limestone, ensuring consistency that met the strict standards of their construction clients. “Our clients have noticed the difference,” Weber notes. “The uniformly sized aggregates mix better in concrete and lay more evenly in road bases, which has helped us win two new long-term contracts. We’re now able to supply more clients without increasing our operational footprint.”
Energy efficiency was another key benefit that surprised the quarry team. The C150 is equipped with a high-efficiency motor that reduces energy consumption by 18% compared to their old crusher, translating to significant cost savings over time. “With energy prices rising across Europe, that 18% reduction has added up to nearly €20,000 in annual savings,” explains Weber. “Combined with lower maintenance costs and higher productivity, the C150 has paid for itself in less than 18 months.”
One year after the C150’s installation, the quarry’s performance metrics tell a compelling story: production capacity has increased by 65%, operational costs have decreased by 30%, and customer satisfaction has reached an all-time high. The crusher has proven its durability even in the quarry’s harsh working conditions, handling abrasive limestone day in and day out without compromising performance. “We chose the C150 because we needed a solution that could grow with our business,” says Weber. “It’s not just a crusher—it’s an investment that has transformed our operations, making us more efficient, competitive, and sustainable. We wouldn’t hesitate to recommend it to any quarry or aggregate producer facing similar challenges.”
For the C150 Jaw Crusher, this German quarry case is a testament to its ability to deliver tangible value in real-world applications. Designed to tackle the toughest primary crushing tasks, it combines power, efficiency, and reliability to help businesses overcome production bottlenecks, reduce costs, and unlock new growth opportunities—proving that the right equipment can turn challenges into competitive advantages.