Cone vs Impact Crusher: Choosing Secondary Crushing
Choosing between a cone crusher and an impact crusher for secondary crushing is one of the most common decisions in plant design. Here is a practical comparison to help you choose.
Cone crusher
- Best for: hard, abrasive rock (granite, basalt, iron ore)
- Crushing method: compression between a mantle and concave
- Product shape: cubic with laminated crushing, but slightly more elongated particles at coarse settings
- Wear cost: low - manganese steel liners last long
- Capacity: high, models from GP100 to HP800 and Symons 3Ft-7Ft
- Best application: secondary/tertiary in hard-rock mining and aggregate plants
Impact crusher (PF)
- Best for: medium-hard, less abrasive rock (limestone, concrete, recycling)
- Crushing method: impact against blow bars and impact plates
- Product shape: excellent, well-rounded cubic product
- Wear cost: higher - blow bars wear faster on hard rock
- Capacity: models from PF1007 to PF1520
- Best application: limestone quarries, aggregate shaping, construction waste recycling
Quick decision guide
| Your material | Choose |
|---|---|
| Hard & abrasive (granite, basalt) | Cone crusher |
| Soft-medium (limestone, gypsum) | Impact crusher |
| Need best cubic shape at low wear cost | Cone crusher |
| Recycling concrete/asphalt | Impact crusher |
| Sand production | VSI crusher |
Rule of thumb
If your rock is harder than about 120 MPa, choose a cone crusher for secondary crushing - the lower wear cost will pay for itself quickly. For softer rock and recycling, an impact crusher gives the best product shape per ton.
DC Machinery supplies both GP/HP/Symons cone crushers and PF impact crushers. Tell us your material and we will recommend the right machine: https://dccrusher.com/contact/
Related resources
- Symons Cone Crusher
- PF Impact Crusher
- HP Series Cone Crusher
- Cone crusher wear parts
- Impact crusher wear parts
- Jaw crusher vs cone crusher
Related Equipment & Parts
Cost Comparison Over Five Years
| Step | What to check |
|---|---|
| Cone - capital cost | Higher per unit, but the frame and shaft outlast several liner sets |
| Impact - capital cost | Lower for the same nominal capacity |
| Cone - wear cost | Mantle and concave change every 3-8 months in hard rock; predictable cost per tonne |
| Impact - wear cost | Blow bars may need changing weekly in abrasive rock; cost per tonne can triple |
| Cone - product shape | Cubical in the right cavity; slight flakiness in coarse cavities |
| Verdict | Hard abrasive rock: cone. Soft or medium limestone with a shape requirement: impact |
Frequently Asked Questions
How do I confirm a model before ordering?
Send your maximum feed lump, target tonnes per hour, required discharge size and rock type. We return a model, cavity, motor power and estimated weight within 24 hours.
Can you supply the whole plant, not just one machine?
Yes. Feeder, crusher, screen, conveyors, control panel and foundation drawings can be supplied as one package, and we export worldwide.
What about spare parts after delivery?
Jaw plates, cone mantles and concaves, blow bars, bushings, bearings and V-belts are kept in stock, matched to your machine model.
Do you provide installation support?
Yes - remote guidance is included, and an engineer can be dispatched to site when required.
Next Step
Send your material, maximum feed size and target tonnes per hour and our engineers will reply with a model recommendation, price and lead time: request a quotation.
Related reading: jaw crusher selection, cone crusher range, crusher wear parts, delivered projects.