Aggregate Industry – Rugged Power & Automation Solutions for Crushing and Material Handling
Crushing and screening aggregates is tough work. Equipment must start under load, run for long hours and endure dust, vibration and shock. Crossman Automation has supported Western Canada’s aggregate producers and quarries for decades. Our deep industry knowledge and partnerships with leading manufacturers allow us to specify, supply and integrate heavy‑duty electric motors, variable‑frequency drives (VFDs) and power‑transmission components that keep your crushers, conveyors and screening systems running reliably and efficiently.
Heavy‑Duty Motors Built for Crushing
Aggregate operations demand motors with high starting torque, rugged construction and long service life. Crossman supplies crusher‑duty and severe‑duty motors from Baldor, U.S. Motors and Brook Crompton—brands trusted in the aggregate sector. Baldor’s crusher‑duty motors, for instance, are designed specifically for belt‑driven rock crushers and other high‑torque applications. They offer horsepower ranges from 5 hp up to 600 hp, with cast‑iron totally enclosed fan‑cooled (TEFC) construction to minimise vibration and keep bearing temperatures low. High‑torque NEMA Design A performance exceeds typical Design C torques, while oversized ball and roller bearings, class F insulation, and 1.15‑1.25 service factors ensure reliable operation under heavy load. These motors meet IP55 protection up to frame size L449 and IP66 for larger 586/7/8 frames, making them ideal for dusty crushing environments. Typical applications include belt‑driven rock crushers, pellet mills, feeders, stackers, overland conveyors, screen decks, augers, screw conveyors and log washers—exactly the equipment used in aggregate and cement plants.
U.S. Motors’ CORRO‑DUTY line, available from 1 hp to 300 hp, is also designed for harsh environments like mining and aggregate. These motors feature all cast‑iron construction, corrosion‑resistant paint, a shaft slinger to protect internal components from dust, stainless steel nameplates and zinc‑plated hardware. They meet NEMA premium efficiency standards and are available in multiple voltages and speeds. U.S. Motors’ crusher duty motors add a premium‑efficient design, IP55 rating, class F insulation and a 1.15 service factor—ensuring they can withstand the shock, vibration and high starting torque required by rock crushers and grinders. By supplying these heavy‑duty motors and customizing them to your application, Crossman helps aggregate producers reduce downtime, extend equipment life and improve productivity.
Variable‑Speed Conveyors – Efficiency and Control
Material handling is central to aggregate production, and conveyors often consume significant energy. Crossman integrates VFDs into belt conveyors to provide variable speed control and deliver measurable savings. According to West River Conveyors, variable speed conveyors allow you to fine‑tune the speed at which your machinery moves bulk materials, reducing power consumption and equipment strain during start‑up and slow‑down. They provide greater flexibility and reduce wear and tear on equipment. By matching conveyor speed with material flow rates and process demands, variable‑speed drives reduce energy consumption and operational costs compared with fixed‑speed systems. Smooth acceleration and deceleration also protect belts, drive pulleys and bearings, leading to longer component life and reduced maintenance costs. Other benefits include improved throughput, reduced risk of jams and spills, and the ability to handle materials of different size, weight and density. Variable‑speed conveyors also generate less noise during start‑up and slow‑down and minimise environmental impacts. Although variable‑speed systems require a higher initial investment, a properly planned installation pays for itself through better returns on productivity, energy costs and production flexibility. Crossman engineers select and program VFDs—often Danfoss or Vacon—to match your conveyor’s load requirements, belt length and terrain. Our single‑source responsibility ensures the motor, VFD and gearbox work together seamlessly.
Power Transmission and Motion Control
Aggregate plants rely on more than just motors and drives. They require gearboxes, couplings, torque limiters, clutches, brakes and tensioning systems that endure shock loads and frequent stops. Crossman supplies gear reducers and shaft mounts from reputable brands to ensure smooth power transfer and proper torque multiplication. Our partnership with Nexen provides clutch and brake solutions designed for heavy‑duty industrial applications. Nexen’s clutches and brakes feature simple designs with few parts, making them easy to install and maintain, and their rugged construction ensures long life. For overload protection, we can add torque limiters or couplings that disengage during jams, safeguarding expensive equipment. By integrating these components into a cohesive system, Crossman delivers reliable material handling with minimal downtime.
Custom Design and Integration
Every aggregate plant is different. Whether you’re running a stationary quarry or a portable crushing spread, Crossman engineers evaluate your process to recommend the right combination of motors, drives and transmission components. We design control panels with dust‑sealed enclosures and ventilation to cope with harsh environments. Our team can include soft‑start functionality to reduce inrush current on high‑horsepower motors and dynamic braking for safe stops. For conveyors with extreme lengths or slopes, we employ regenerative VFDs and load‑sharing systems that balance torque and prevent belt slip. We also provide network communications to integrate drives with your supervisory control systems.
Partnerships with Leading Manufacturers
Crossman’s product offering draws from top manufacturers in the mining and aggregate space:
U.S. Motors – CORRO‑DUTY and Crusher‑Duty lines feature cast‑iron construction, dust protection and premium efficiency for severe environments.
Brook Crompton and Parkhaven – Offer TEFC and explosion‑proof motors, including NEMA and IEC configurations, with robust, highly efficient designs.
Nexen – Provides torque limiters, clutches and brakes with simple designs and corrosion‑resistant finishes, ideal for dusty, abrasive environments.
WEG and Worldwide Electric – Supply heavy‑duty motors, gear reducers and VFDs at various price points.
These partnerships give you access to a comprehensive inventory of motors, drives and transmission products, ready for rapid shipment from our Edmonton facility.
Why Choose Crossman Automation?
Deep Industry Knowledge: Decades of experience in aggregate and mining mean we understand the unique challenges of crushing and material handling.
Integrated Systems: We design and build complete motor‑and‑VFD packages that deliver high starting torque, energy efficiency and long service life.
Rugged Products: Our crusher‑duty and severe‑duty motors feature cast‑iron construction, oversized bearings, IP55/IP66 protection and high service factors; U.S. Motors’ CORRO‑DUTY motors add corrosion-resistant paint, shaft slingers and stainless steel hardware.
Energy & Cost Savings: Variable‑speed conveyors reduce power consumption, wear and noise, and improve throughput. Our VFD packages can be programmed to deliver optimum speed and torque across your entire plant, paying for themselves through operational savings.
Single‑Source Responsibility: From equipment selection and control design to commissioning and ongoing support, Crossman handles the entire process. We stock replacement parts and provide field service to minimize downtime.
Let’s Build Your Aggregate Solution
Whether you need to outfit a new crushing plant, upgrade old motors to premium‑efficiency models or optimize your conveyor speeds, Crossman Automation can help. Our engineers will evaluate your application, propose a tailored solution and provide the rugged motors, energy‑efficient drives and reliable power‑transmission components needed to keep your aggregate operation running smoothly. Contact us today to learn how we can improve uptime, reduce energy costs and extend equipment life in your quarry or gravel pit.