Higher-quality low-chrome blow bars: 42,000 tons processed with ~40% wear life left on the first side and a much better fit.
A crushing operation used low-chrome blow bars with an average wear life of about 12 weeks (90,000 tons per set), but poor surface finish caused recurring installation problems.
Even when installed correctly, the wedges didn't seat cleanly, leaving a small gap. When the bars needed to be flipped, wear and inconsistent surface finish made installation even more difficult. Over time, the operation had effectively accepted the additional downtime and labor as part of its normal operating cost.
After identifying the installation and flipping issues, Buffalo gathered the required part numbers and worked with its quarry-supply team to develop a competitive proposal for higher-quality low-chrome blow bars.
Although the Buffalo bars carried a higher initial price, the team focused on the improved quality and finish of the components. After multiple discussions, site visits, and product-quality reviews, the operation agreed to trial a set.
The trial set has processed approximately 42,000 tons with an estimated 40% of the wear life remaining on the first side before the flip.
The operation has also reported noticeably better installation fit and positive early wear performance. If that performance continues through the flip and second side, the improved fit and durability could reduce annual downtime and labor associated with blow bar installation.
