Since 2007 · 40+ Projects · 200 TPH High Output Cone Crushers · Karur, Tamil Nadu
The cone crushers beat our first design. So we redesigned the nozzles.
Our work in the Karur region of Tamil Nadu began in 2007 with "Sri Murugan Bluemetals", covering both machine side dust control and roadside RainGun dust control at the same site. It did not stay a single project for long — more than 10 mining industries in the region were erected by us in that same year.
Karur's crushers are not small. All of them are advanced 200 TPH high output cone crushers, and we install dust control on both the primary jaw crusher and the cone crusher side. Those are two different dust problems on the same plant: the jaw crusher throws coarse dust at the feed end, while the cone crusher produces a far finer and heavier cloud. Each gets its own nozzle layout.
In 2010 we faced real risk in this region on cone crusher dust control. The cone crushers were producing much more dust than our systems of that time were sized to handle. On a 200 TPH plant running all day, a dust system that cannot keep up is not a minor shortfall — it is a compliance and a health problem at the customer's site.
The fix was to put extra capacity nozzles into this type of crusher — more misting capacity concentrated where the cone crusher generates its cloud, rather than switching to a different technology.
The constraint that made it difficult is the one worth understanding: our system never affects the output quality of the bluemetals. The crude way to suppress more dust is simply to add more water — but wet product is damaged product, and a customer selling M-Sand and graded bluemetal cannot accept that. The extra capacity had to come from mist particle size and nozzle placement, not volume.
That design has held since. Karur now stands at more than 40 projects — around 90% of the mining industries in the region — spanning machine side dust control on jaw and cone crushers, plus road and stock yard RainGun projects.
| Region | Karur, Tamil Nadu, India |
| Started | 2007 — with "Sri Murugan Bluemetals" |
| First Year | More than 10 mining industries erected |
| Projects to Date | 40+ · roughly 90% of the region's industries |
| Plant Type | Advanced 200 TPH high output cone crushers |
| Systems Installed | Primary jaw crusher + cone crusher side dust control; road and stock yard RainGun projects |
| 2010 Design Change | Extra capacity nozzles for cone crushers |
| Product Impact | None — output quality of bluemetals unaffected |
Karur is one of six regions where we have concentrated dust control work. See the full dust control customer overview, or the Chennai and Kanchipuram region, where M-Sand crushers of the same 200 TPH class made our system a condition of licence renewal.
A cone crusher simply produces much more dust. We found this out in the Karur region in 2010, where the advanced 200 TPH high output cone crushers generated far more dust than the systems of the time were sized for. The solution was extra capacity nozzles fitted specifically for that crusher type — more misting capacity at the point of generation, rather than a different technology.
No. Even with the extra capacity nozzles fitted to the cone crushers in the Karur region, our system has never affected the output quality of the bluemetals. This matters because the obvious way to suppress more dust is to add more water, which would damage the product — the design works by mist particle size and placement instead of volume.
Yes. In the Karur region we install dust control on the primary jaw crusher and on the cone crusher side. They are different dust problems on the same plant — the jaw crusher throws coarse dust at the feed end, the cone crusher generates a much finer and heavier cloud — so each needs its own nozzle layout.
More than 40 projects, covering roughly 90% of the mining industries in the region. The work started in 2007 with Sri Murugan Bluemetals and more than 10 industries were erected in that first year alone.
Tell us your crusher type and TPH. We have been sizing nozzles for 200 TPH cone crushers since 2007 — without wetting the product.
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