Achieving perfect consistency in products like medicines, herbal teas, and spices is not a matter of chance; it is the result of precise processing. But what makes this possible? A universal crusher.

​This versatile machine handles a wide variety of materials, from fibrous herbs to hard minerals, with remarkable efficiency. So, what is a universal crusher? Think of it as the ultimate multi-purpose tool for material size reduction, designed to grind and crush various substances with one machine.

​This guide is all about understanding the role of universal crushers in modern manufacturing, core components, and applications across different industries.

What is a Universal Crusher?

A universal crusher is a multipurpose industrial equipment that grinds, crushes, and reduces the size of different materials. It works by using high-speed rotating components, such as toothed discs or blades. These components break down substances through impact, friction, and shearing to produce a consistent and uniform particle size.

​The value of a universal crusher lies in its multipurpose nature. This is why it is essential for manufacturing across different industries like pharmaceuticals, food, chemicals, and herbal products.

Inside the Universal Crusher: Key Components

A universal crusher has a simple structure composed of different key components. These components work together to reduce the size of various materials. We will discuss these essential parts one by one to understand their specific roles in the crushing process.

1. Hopper and Feeder

A hopper is a hollow part located at the top of the machine where the raw material is initially loaded. A feeder is a vibrating component that controls the speed at which the material enters the crushing chamber.

2. Air Inlet Port

The air inlet port is an open area above the crushing chamber. Its purpose is to provide a continuous flow of air. This airflow is crucial for material smashing, as it helps move particles through the chamber and prevents them from sticking to the sides.

3. Crushing Discs/Blades

They are either a set of rapidly rotating toothed discs or high-speed blades or hammers. These components break down the material through powerful impact, friction, and shearing. The specific design of these discs enables the machine to handle various types of feed materials with great precision.

4. Crushing Chamber

The cruising chamber is the core of the machine where all size reduction takes place. It is an enclosed space that contains the cruising elements. The chamber’s design is robust and built to handle the intense forces required to process a wide range of materials.

5. Crushing Liner

It is a stationary plate or surface that works in conjunction with the moving discs or blades. The material is crushed between these two surfaces. This liner is often made of hardened, wear-resistant steel to handle the constant abrasion and impact from the materials being crushed.

6. Sieve or Screen

The sieve or screen is located at the bottom of the chamber and controls the final output size of the crushed material. The crushed particles must be small enough to pass through the mesh of the screen. They will be later discharged through the powder outlet port.

7. Motor and Drive System

A powerful electric motor provides the energy to drive the rotating blades or discs at high speed. The drive system includes belts, pulleys, or gears, which transfer this power from the motor to the crushing mechanism.

How Does a Universal Crusher Work?

A universal crusher works by using a combination of impact, shear, and friction to reduce the size of materials. The process is quite convenient and consists of the following key stages:

1. Feeding

In the initial phase, raw material is introduced into the machine through a hopper. A feeding mechanism controls the rate at which the material enters the crushing chamber. It prevents the material from getting clogged and ensures a steady process.

2. Crushing

The loaded material is passed into the crushing chamber. The material is milled and ground by the rotation of a toothed disc or blades. These substances are well-crushed by the speedy movement of opposing blades and knives. The constant friction of the knives and teeth further reduces the material’s size and turns it into a powder.

3. Sizing

The crushed material falls towards the bottom of the chamber through an integrated sieve or screen. The machine only allows particles of  the desired size to pass through the mesh of this screen. Any larger particles are retained inside the chamber for further crushing.

4. Discharge

Once the particles are reduced to the correct size, they pass through the powder outlet port and are discharged through the machine. The finished product is then collected in a designated container and transferred to the next stage of processing.

Key Features and Benefits of a Universal Crusher

A universal crusher is a critical piece of equipment in many industries. Here are a few of its key features and benefits that highlight how it provides value:

1. Versatile Design 

The universal crusher is a multi-purpose machine designed to handle a wide range of materials. Its robust construction allows it to process everything from soft, fibrous herbs to hard minerals and crystalline chemicals. The adjustable sieve or screen, the machine gives operators precise control over the final particle size to meet your specific requirements. 

2. Efficient Operation 

This machine achieves high efficiency through its powerful crushing mechanism. A strong motor drives rapidly rotating components, such as toothed discs or blades, at high speeds. These elements work together to break down materials quickly through a combination of impact, friction, and shearing forces. This significantly reduces processing time and increases overall production output.

3. Size Reduction

The primary function of a universal crusher is to reduce the size of solid materials through grinding and crushing. It takes larger substances and converts them into fine, uniform powders.

For example, in the pharmaceutical industry, machines process bulk drug intermediates. These intermediates are used in the formulation of final medicines for a uniform composition of tablets and capsules.

4. Particle Sizing

A universal crusher is an essential pharmaceutical equipment to maintain the right particle size.  This equipment reduces raw materials to a fine, consistent powder. 

The right particle size directly affects a drug’s effectiveness. A smaller particle size increases the drug’s surface area. This allows the active ingredients to dissolve and absorb faster in the body.

5. Hygienic Processing

Universal crushers are designed to meet strict quality standards set by the World Health Organization. They are typically made of stainless steel with smooth, polished interior surfaces. This design prevents materials from sticking to the walls, which minimizes product loss and prevents cross-contamination between different batches.

​The sanitary construction also helps you comply with Good Manufacturing Practice (GMP) standards, as the equipment is clean, and the final product is pure and safe for consumption.

Core Functions of a Universal Crusher

A universal crusher is a critical piece of equipment in many industries. Here are a few of its core functions that highlight how it provides value:

1. Size Reduction

The primary function of a universal crusher is to reduce the size of solid materials through grinding and crushing. It takes larger substances and converts them into fine, uniform powders.

For example, in the pharmaceutical industry, machines process bulk drug intermediates. These intermediates are used in the formulation of final medicines for a uniform composition of tablets and capsules.

2. Particle Sizing

A universal crusher is an essential pharmaceutical equipment to maintain the right particle size.  This equipment reduces raw materials to a fine, consistent powder.

The right particle size directly affects a drug’s effectiveness. A smaller particle size increases the drug’s surface area. This allows the active ingredients to dissolve and absorb faster in the body.

3. Hygienic Processing

Universal crushers are designed to meet strict quality standards set by the World Health Organization. They are typically made of stainless steel with smooth, polished interior surfaces. This design prevents materials from sticking to the walls, which minimizes product loss and prevents cross-contamination between different batches.

​The sanitary construction also helps you comply with Good Manufacturing Practice (GMP) standards, as the equipment is clean, and the final product is pure and safe for consumption.

Use of Universal Crushers in Different Industries

The global pharmaceutical crusher machine market is valued at $374 million. However, this equipment is not limited to the pharmaceutical industry alone. Its multipurpose design and ability to handle various materials make it essential for manufacturing in the food, chemical, and pharmaceutical industries.

1. Pharmaceuticals

The pharmaceutical industry remains the biggest consumer of universal crushers. They are used to crush medicinal herbs, bulk drug intermediates, and other chemical compounds. This is necessary for creating medicines with a uniform composition and a specific dissolution rate.

2. Food and Herbal Products

The hygienic design of these crushers makes them perfect for the food industry. They are used to grind a wide variety of ingredients, including spices like chilli and pepper, grains such as corn and rice, and crystalline substances like sugar and salt. Universal crushers can also crush dried herbs and roots to be utilized in teas, supplements, and other products.

3. Mineral and Chemicals

Universal crushers can process minerals and chemicals in smaller, controlled batches. They can handle substances like pigments, dyes, and other compounds. Their durable design allows them to crush a range of materials. This includes certain brittle minerals and recycling materials like concrete.

Choose The Best Crushing Solutions With Finetech

A universal crusher is an inevitable part of industries that manufacture food, drugs, and other products. It benefits the manufacturing process by increasing performance and reducing waste and production time.

If you are looking for a cutting-edge solution, we recommend Finetech. As China’s leading pharmaceutical equipment supplier, Finetech’s universal crushers provide a complete solution for various industries. From installation to customization, we offer unparalleled support.

Get in touch with us and discover your perfect solution.

FAQs

1. What are the key safety precautions for operating a universal crusher?

Before operating a universal crusher, always ensure you are wearing appropriate personal protective equipment (PPE), such as safety glasses, gloves, and a dust mask.

Make sure to lock and tag the machine before any maintenance or cleaning to prevent any accidental startup. Additionally, never feed materials that exceed the machine’s recommended hardness or size to prevent damage to the crushing elements.

2. How do you perform cleaning and maintenance on a universal crusher?

Regular cleaning is extremely important to maintain hygiene and prevent cross-contamination.  The process involves disassembling key parts to remove residual materials, especially in sanitary-grade machines.

Maintenance includes checking for wear on the crushing elements and liners. Also, make sure that the motor and drive system are lubricated and in good working condition.

3. What factors should be considered when buying a universal crusher?

Key factors to consider include the type and hardness of the material you will be crushing. It is also important to choose a model with a suitable size for your space and with features like a dust collector and a water-cooling system if required.