Author: YZH Publish Time: 2025-10-26 Origin: https://www.yzhbooms.com/
Got a call last month from a mine superintendent in Nevada. "Kevin," he says, "I just had another incident with manual jam clearing. Nobody got hurt this time, but it was close. I need to do something different."
This conversation happens more often than I'd like. Mining operations everywhere are dealing with the same challenge: how to keep crushers running safely and efficiently when material jams up.
The traditional approach - sending workers into crusher chambers with bars and hammers - is dangerous, slow, and expensive. There's a better way, and it's transforming how mines handle material flow problems.
Most mine managers know manual jam clearing is risky, but they don't always see the full cost.
Safety Risks Everyone Knows About
Workers in confined spaces around massive machinery. Heavy material that could shift unexpectedly. Limited escape routes. High noise levels. Dust and poor visibility.
Every time someone climbs into a crusher chamber, you're rolling the dice on a serious injury.
The Productivity Hit
But here's what really hurts: the time it takes to clear jams manually.
First, you've got to shut down the crusher safely. Lock out all power sources. Wait for everything to stop moving. Then workers can enter the chamber.
The actual clearing work is slow and difficult. Workers are using hand tools to move material that the crusher couldn't handle. It's exhausting work in a confined space.
After clearing, you need to inspect for damage, restart systems, and get back to normal operation.
Start to finish, you're looking at hours of downtime for what should be a quick fix.
The Ripple Effect
When your primary crusher goes down, everything downstream stops. Conveyors, secondary crushers, processing equipment - all sitting idle while you clear a jam.
In high-capacity operations, every hour of downtime costs serious money. Not just in lost production, but in fixed costs that keep running whether you're producing or not.
A pedestal boom system eliminates most of these problems by keeping workers out of danger zones while dramatically reducing clearing time.
Remote Operation
The operator controls the boom from a safe location, usually an air-conditioned cab with good visibility of the work area. No one needs to enter the crusher chamber.
The hydraulic hammer can break up jammed material from outside the danger zone. Much safer, and much faster than manual methods.
Quick Response
When material jams, the boom operator can respond immediately. No shutdown procedures, no waiting for lockout/tagout, no safety meetings before entry.
Position the boom, start breaking, clear the jam, and get back to production. What used to take hours now takes minutes.
Precision Breaking
Good boom systems allow precise positioning of the hydraulic hammer. Operators can target specific problem areas without damaging crusher components.
This precision reduces the risk of crusher damage during jam clearing, which can be expensive and cause extended downtime.
The safety benefits go beyond just keeping workers out of crusher chambers.
Elimination of Confined Space Entry
Most crusher chambers qualify as confined spaces, requiring special procedures, atmospheric monitoring, and rescue standby. Boom systems eliminate most confined space entries.
Reduced Exposure to Hazards
No exposure to falling material, moving machinery, noise, dust, or ergonomic hazards from manual breaking work.
Better Emergency Response
When something goes wrong, boom operators can respond quickly without putting additional people at risk.
Improved Visibility
Boom operators typically have better visibility of the work area than workers inside crusher chambers. They can see potential hazards and react accordingly.
The productivity improvements from boom systems are dramatic and immediate.
Faster Jam Clearing
Instead of hours, jam clearing takes minutes. The time savings alone often justifies the investment.
Reduced Crusher Wear
Proper jam clearing with precision breaking reduces damage to crusher components. Less damage means longer component life and fewer expensive repairs.
Improved Material Flow
Boom systems can also help with material flow management, not just jam clearing. Operators can break oversized material before it causes problems.
Elimination of Safety Stops
No more production stops for safety meetings, permit preparation, and other procedures required for manual jam clearing.
While every operation is different, the improvements are consistently significant.
Downtime Reduction
Most operations see dramatic reductions in jam-related downtime. What used to shut down production for hours now gets resolved quickly.
Productivity Increases
Better material flow, less crusher wear, and reduced downtime all contribute to higher overall productivity.
Safety Improvements
Eliminating manual jam clearing removes a major source of injury risk from mining operations.
Return on Investment
The combination of productivity gains and cost savings typically provides attractive returns on boom system investments.
Boom systems provide value beyond just clearing jams.
Preventive Maintenance
Boom systems can help with crusher maintenance by providing safe access for inspection and minor repairs.
Material Sizing
Breaking oversized material before it reaches the crusher reduces wear and improves throughput.
Operational Flexibility
Having a boom system gives operators more options for dealing with material flow problems.
Future Capacity
As mines expand and throughput increases, boom systems can handle higher volumes without proportional increases in labor.
Not all boom systems deliver the same results. Here's what separates good systems from great ones:
Reliable Operation
The system needs to work when you need it. Downtime for boom repairs eliminates the productivity benefits.
Operator Comfort
Comfortable operators are productive operators. Good visibility, ergonomic controls, and climate-controlled cabs make a difference.
Precision Control
The ability to position the hammer precisely reduces crusher damage and improves clearing efficiency.
Service Support
When problems occur, you need fast, competent service to minimize downtime.
Getting the full benefits requires proper implementation.
Site Integration
The boom system needs to be properly integrated with your existing equipment and procedures.
Operator Training
Operators need proper training to use boom systems effectively and safely.
Maintenance Programs
Like any equipment, boom systems need regular maintenance to perform reliably.
Procedure Development
New procedures for boom operation need to be developed and integrated with existing safety and operational protocols.
Boom systems represent a fundamental shift in how mining operations handle material flow problems.
Safety Culture
Installing boom systems demonstrates commitment to worker safety and can improve overall safety culture.
Operational Excellence
Boom systems are part of a broader trend toward automation and remote operation in mining.
Competitive Advantage
Operations with boom systems can achieve higher productivity and lower costs than those relying on manual methods.
Future Readiness
As labor costs increase and safety requirements become more stringent, boom systems position operations for future success.
The business case for boom systems is usually straightforward.
Quantifiable Benefits
Reduced downtime, improved productivity, and lower labor costs provide measurable returns.
Risk Reduction
Eliminating manual jam clearing reduces injury risk and associated costs.
Competitive Positioning
Boom systems help operations achieve cost and productivity advantages over competitors.
Long-term Value
Boom systems typically provide benefits for many years, making them good long-term investments.
Considering a boom system for your operation? Every mine is different, and the specific benefits depend on your current procedures, material characteristics, and operational requirements. Contact us now to find out how boom systems could improve safety and productivity in your specific situation.
