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| Model | Roll Diameter (mm) | Roll Length (mm) | Max Feed Size (mm) | Throughput (t/h) | Motor Power (kW) |
|---|---|---|---|---|---|
| ZKDG1060 | 1,000 | 600 | ≤35 | 110-130 | 75×2 |
| ZKDG1187 | 1,100 | 870 | ≤35 | 210-240 | 132×2 |
| ZKDG1110 | 1,100 | 1,000 | ≤35 | 240-270 | 160×2 |
| ZKDG1390 | 1,300 | 900 | ≤35 | 300-350 | (250-315)×2 |
| ZKDG1410 | 1,350 | 1,000 | ≤35 | 400-550 | (355-400)×2 |
Notes: throughput depends on material hardness, feed gradation, moisture and the set roll gap; figures assume dry, friable to medium-hard material with a well-graded feed within the maximum feed size. All models are twin-motor driven. The discharge size is controlled by the roll gap within the working adjustment range. Contact Ormaise with your material analysis and product size target for a model and roll surface recommendation.
Stock-listed crushing and screening equipment manufacturer, serving 2,000+ operations since 2003.
A roller crusher handles secondary and fine crushing where a controlled product size and a low fines share matter. Classic duties are coal and coke preparation, limestone, gypsum and similar soft to medium-hard or friable materials, and fine crushing of ore. The ZKDG series is widely used in the sand making process of metal and non-metal mines, taking pre-crushed feed and turning it into a saleable fine product with minimal over-crushing.
Two counter-rotating rolls draw the feed into the nip between them and crush it by compression in a single pass. The crushed product falls through by gravity, and its size is set by the gap between the rolls. When an uncrushable object enters, the movable roll retreats against hydraulic cylinders or springs to let it pass, then returns to the working gap automatically. The drive runs through twin motors, reducers and universal couplings, so the two rolls keep turning even as the gap moves.
A single roll crusher uses one roll working against a fixed breaker plate and handles coarse primary duty on soft materials. A double roll crusher, the design of the ZKDG series, uses two rolls and covers secondary and fine crushing with a controlled product. Triple and four roll crushers stack two pairs of rolls in one frame so the machine does two reduction stages in series, giving a higher total reduction ratio in one pass. The right configuration follows the feed size, the product target and how much reduction must happen in one machine.
Toothed rolls grip and tear the feed, so they accept larger lumps relative to roll diameter and handle sticky or clay-bearing material that would slip on a smooth surface; they are the standard choice in coal preparation. Smooth rolls take smaller, well-prepared feed and produce the most even fine product with the least oversize, which is why smooth double roll machines are used for fine crushing and sand making. Corrugated and profiled surfaces sit between the two. Tell us your feed size, material and product target and we will recommend the surface.
Each machine earns its place differently. A cone crusher gives much higher capacity and reduction on hard, abrasive rock, and an impact crusher gives high reduction and good shape on softer stone. The roller crusher works at moderate reduction with very low fines generation, a tightly controlled top size, simple structure and low energy use per tonne. On coal, coke, friable ores and sand-making duty with pre-crushed feed, that behaviour is exactly what the product needs, and the machine is simpler and cheaper to run than the alternatives.
Yes, and it is one of the main duties of the ZKDG series. Fed with screened material within the maximum feed size, the rolls produce a fine, well-shaped product with a controlled top size and a low ultra-fines share. Compared with impact-based sand making, the roller crusher uses less energy per tonne and generates less dust, at a lower capacity per machine. Many mine sand-making lines use a roller crusher after a cone crusher or vertical shaft impactor stage, with a screen closing the circuit.
The roll shells are the main wear item. Wear shows first as an uneven gap and a coarser product at the centre of the rolls, so product gradation is the practical wear indicator. Shells are replaced as assemblies; the design of the ZKDG series keeps the change-out straightforward, and welding repair of worn surfaces is possible where the base material allows. Keeping the feed within the size limit and distributing it evenly across the roll width is the most effective way to extend shell life.
Ormaise supplies original-specification roll shells, bearings and drive components matched to the build record of each machine, together with commissioning support, operator training and remote diagnostics. Every ZKDG crusher ships with its factory test report, so service and parts questions are answered against the actual data of your unit throughout its working life.
A roller crusher is one of the oldest crusher designs still in daily use, and the reason is simple: it does one thing very well. Feed falls between two rolls turning toward each other, is drawn into the nip and crushed by compression in a single pass, and the product drops through by gravity. The largest particle that a pair of rolls can grip is set by the nip angle, which links feed size to roll diameter; that is why roll crushers are fed with pre-crushed, screened material and why their product carries such a controlled top size. There is no impact, no repeated attrition and no grinding zone, so over-crushing and fines generation stay low.
The roll crusher family covers several configurations, and the names describe them directly:
| Type | Structure | Typical Duty |
|---|---|---|
| Single roll crusher | One roll against a fixed breaker plate | Coarse primary crushing of soft, friable material such as coal |
| Double roll crusher | Two counter-rotating rolls; smooth or toothed shells | Secondary and fine crushing; the ZKDG configuration |
| Triple roll crusher | A single-roll stage feeding a double-roll stage in one frame | Two-stage reduction in one machine on soft to medium material |
| Four roll crusher | Two pairs of rolls in series in one frame | High total reduction to a fine product in a single pass |
| Toothed roll crusher | Rolls with teeth or segments that grip and tear the feed | Coal preparation, sticky or clay-bearing feed, larger lumps |
| Smooth roll crusher | Plain ground shells | Fine crushing and sand making with a prepared, sized feed |
One name worth separating from this family: the high pressure grinding rolls machine, often shortened to HPGR or called a roller press, is a different class of equipment that compacts a full material bed at much higher pressure for ore comminution ahead of grinding mills. The Ormaise GM series covers that duty; the ZKDG roller crusher covers classic crushing and sand making.
Modern plants lean on cone crushers and impact crushers for most hard-rock work, and rightly so. The roller crusher keeps its place wherever the product specification punishes over-crushing: coal and coke preparation, where fines are waste; friable ores and industrial minerals, where a narrow size band sells at a premium; and mine sand making, where a controlled top size and low ultra-fines share simplify the classification circuit. In these duties the machine offers a short list of practical advantages: simple structure, low installed power per tonne, low dust, direct product sizing through the gap, and automatic tramp relief built into the frame.
In metal and non-metal mines, the ZKDG roller crusher typically sits after a cone crusher or a vertical shaft impactor and works in closed circuit with a vibrating screen. The feed arrives already sized below thirty-five millimetres, the gap is set to the sand specification, and oversize returns for another pass. Because the product band is narrow, the screen load is predictable and the circuit is easy to balance. Where the plant also sells shaped coarse aggregate, the VSI handles shaping while the roller crusher makes the fine fraction, and the two machines share the closed-circuit screens.
Three habits decide how well a roller crusher runs. First, set the gap to the product target and check it as the shells wear; an opening gap shows up as a coarser product long before it shows up on the rolls. Second, feed evenly across the full roll width, because concentrated centre feeding grooves the shells and ruins the gap profile. Third, respect the feed size limit: oversize that the nip angle cannot grip will ride the rolls, cut throughput and accelerate wear. Follow these, and the roll shells deliver long, even service; neglect them, and the shells tell you within weeks.
