View of Senya 5 rock crusher at work with high output

Many people ask about the output size possible with our Senya 5 MICRO Crusher.

One of the biggest advantages of the Senya 5 is its ability to produce some of the most valuable and usable sizes of material on the first run. Larger crushers often have to recycle material to get down to the smaller sizes, or those smaller sizes are simply a byproduct of the first crushing pass.

In fact, many Senya 5s are used as a final crusher behind larger machines that can only produce material in the 5- to 6-inch range.

We officially say the Senya 5 produces material from approximately 3/4 inch to 3 inches, but the actual range is much wider than that.

It all comes down to the jaw gap and the type of material being crushed.

The hardness and brittleness of the material have a major impact on the final output size. Approximately 80% of the crushing occurs in the upper portion of the jaw, where the material is squeezed against itself, so every type of material is going to crush a little differently.

The best way to dial in the output you want is simple: run some material, adjust the jaw gap, and find the setting that gives you the maximum amount of the sizes you want to produce.

Why We Use Granite in Our Crusher Videos

It is important to point out that in almost all of our videos, we use hard granite rip rap.

We do this for a reason.

It shows the extreme crushing power of the Senya 5 and gives you a much better idea of what the machine can actually handle than crushing easy material.

Competitors may advertise higher tons-per-hour ratings, but material type can make a huge difference in real-world production. In fact, our crushers come close to the real tons per hour of competitor machines rated at twice the tons per hour.

That is why we like to demonstrate what our machines can do with hard rock.

Concrete crushers are for Sissy’s, we make ROCK CRUSHERS at Senya crushers.

For those asking for more concrete videos, those are coming too.

Truthfully, asking for concrete video from our crushers is like asking to see Michael Jordan play in a WNBA game!!!

We will also be showing more calibrated comparisons using our stacker conveyor scale so you can see the true measured difference between concrete and granite in real tons per hour with the Senya 5.

Using the SP1 MICRO Screen Plant to Sort Your Material

Now back to product size.

The Senya SP1 MICRO Screen Plant is invaluable because it allows you to sort and grade three different sizes of material.

The standard screen sizes produce approximately:

  • 2 to 3 inches
  • 1 to 1.5 inches
  • 3/4 inch minus

The largest material comes off the left discharge conveyor, the middle size comes off the right, and the smallest material comes off the back of the screen plant.

Custom screen sizes are also available down to approximately 1/8 inch and can easily be swapped out depending on what you need to produce.

How the Senya 5 Jaw Gap Is Adjusted

The jaw gap is determined by the shims placed behind the jaw plate.

The Senya 5 comes with two 10 mm, two 8 mm, and two 6 mm shims, with one of each typically set up in the jaw to target an approximate 1- to 1.5-inch output.

Additional shims are always available if needed, but that should rarely be the case.

See our video on how to adjust the jaw gap, also available anytime under the Maintenance tab on SenyaCrushers.com.

There are no hydraulics involved in the adjustment.

As with everything on the Senya 5, the simplicity in design minimizes the number of things that can go wrong. Once you have done it a time or two, the adjustment can easily be completed in about 15 minutes, and the right ratchet and square socket wrenches can make it even faster and easier.

No Shims: Approximately 4- to 6-Inch Material

You can even remove all of the shims and produce the same larger material that many bigger crushers produce.

With no shims installed, you can get material in roughly the 4- to 6-inch range.

At this setting, almost all of the material will come off the left conveyor of the SP1 Screen Plant, with smaller amounts coming off the other two conveyors. The majority of the material output will typically fall in roughly the 2- to 5-inch range.

Example of the larger finished material produced at this setting.

One 10 mm Shim: Mostly 2- to 4-Inch Material

With one 10 mm shim plate in place, the majority of the material will be approximately 2 to 4 inches, with some 1- to 1.5-inch material and minimal 3/4-inch material and fines coming off the back.

10 mm + 8 mm Shims: More 1- to 1.5-Inch Material

Add an 8 mm shim along with the 10 mm shim and you will see a similar overall output, but with a larger percentage of the material falling into the 1- to 1.5-inch range.

This is where you can really start to see how adjusting the jaw setting changes the percentage of each finished product size.

10 mm and 8 mm shims visible at the side of the jaw housing.

10 mm + 8 mm + 6 mm: Our Preferred Setting

The 10 mm, 8 mm, and 6 mm shims create a total 24 mm shim setting.

This is the setting the Senya 5 ships with because it generally produces the best mix of material sizes for most customers.

Depending on the hardness and brittleness of the material, you can expect approximately:

  • 5% to 10%: 2- to 3-inch material
  • 60% to 65%: 1- to 1.5-inch material
  • 30% to 35%: 3/4-inch minus

This is probably the best setting if your goal is to produce the largest amount of 1- to 1.5-inch material.

10 mm, 8 mm, and 6 mm shims visible at the side of the jaw housing.

Here is what the finished material looks like at this setting:

What Happens With Concrete at the Same Setting?

Using the same 24 mm shim setting, we also ran concrete core material through the Senya 5.

The difference is immediately noticeable.

Compared with the hard granite we normally use, concrete is easy work for the Senya 5.

The oversize and mid-size concrete products are similar to the granite output, while the 3/4-inch minus looks much the same but may contain slightly more fines because concrete tends to crumble more easily.

Again, concrete is the easy stuff.

We show granite because we want you to see what this crusher can really do.

3/4″ Minus looks the same as Granite

30 mm Shim Setting: More Mid-Size and Small Material

With a 10 mm, 8 mm, 6 mm, and an additional 6 mm shim installed, you reach a 30 mm shim setting.

At this setting, the vast majority of the output shifts into the mid-size and smaller material ranges.

If your goal is to increase the amount of smaller finished material coming directly off the crusher, tightening the jaw gap gives you that ability.

10 mm, 8 mm, 6 mm, and 6 mm shims visible at the side of the jaw housing.

34 mm Setting: Getting Down to 3/8-Inch Material

At approximately a 34 mm setting, the jaw teeth are almost touching during the throw stroke.

You could potentially tighten the jaw a little more and produce material approaching 3/8-inch pea gravel, depending on what you are crushing.

Of course, the smaller you crush, the more your tons per hour will be affected.

At extremely tight settings, production may fall to approximately 20 to 25 tons per hour, depending on the material and operating conditions.

That is about as tight as you can get on the Senya 5.

At this setting, there will be very little oversize material, slightly smaller mid-size material closer to 1 inch, and a much larger amount of 3/4-inch minus coming off the back of the screen plant.

10 mm, 10 mm, 8 mm, and 6 mm shims visible at the side of the jaw housing.

3/4″ Minus

Some Applications Go Even Smaller

You can perfectly align the jaw teeth so they are almost touching during the throw stroke and potentially produce even smaller material.

We have gold and precious metal miners who use the Senya 5 this way before feeding material into a ball mill.

The smaller the material entering the ball mill, the easier it is on the mill and the crushing balls.

That shows just how much flexibility you have with the Senya 5.

Remember to Adjust for Jaw Plate Wear

As your jaw plates wear over time, you will eventually need to add shims to maintain the same finished product size.

You will know when it is time because your material will gradually begin coming out a little larger.

Also remember that Senya jaw plates can be flipped to get additional life out of them, and we keep replacement jaw wear plates in stock.

Valuable Material on the First Run

As you can see, one of the biggest advantages of the Senya 5 MICRO Crusher is its ability to produce the most valuable aggregate sizes on the first run while still maintaining strong tons-per-hour production.

You can adjust the machine to produce larger 4- to 6-inch material, dial it into the highly valuable 1- to 1.5-inch range, produce large amounts of 3/4-inch minus, or even get down toward 3/8-inch material for specialized applications.

It all comes back to the crushing power of the machine.

It’s all in the crushing power of our machinery, overbuilt to handle just about anything you can feed it with ease. Ready to dial in the right output for your operation? Contact Senya Crushers to talk through your material, production goals, and the setup that will get you the results you need.