A VSI can produce from 100 to over 500 tons per hour depending on rotor size, feed gradation, material hardness, speed setting, and wear part condition. Plants using premium carbide rotor tips and balanced rotors maintain stable high output with less downtime. With optimized configuration, many aggregate producers sustain 250–400 TPH in daily operations.
What Is a Vertical Shaft Impactor?
A vertical shaft impactor is a high-speed crusher that throws stone against stone or anvils using centrifugal force. This impact action breaks rock into cubical shapes, ideal for concrete and asphalt. Compared with cone crushers, VSIs create less flaky material and finer sand.
Rettek manufactures carbide rotor tips, anvil inserts, and rotor wear parts that help keep impact energy consistent. Because Rettek controls alloy batching, pressing, and vacuum sintering in-house, customers benefit from stable performance and predictable wear life across different VSI brands.
| VSI Type | Typical Application | Core Advantage |
|---|---|---|
| Open Rotor | Sand production | Maximum throughput |
| Closed Rotor | Coarse aggregates | Better size control |
| Anvil Ring | Recycling material | High versatility |
How Is VSI Crusher Capacity Calculated?
VSI capacity is estimated from feed size, rotor speed, circuit layout, and material work index. Higher rotor tip speed increases breakage but may reduce tonnage.
A simplified approach is to multiply the feed rate by expected breakage ratio and adjust for recirculation load in closed circuits. For example, a plant targeting 120 TPH finished product at 30% breakage needs about 400 TPH internal load. Rettek carbide rotor tips help maintain this capacity by reducing speed loss caused by abrasion.
What Factors Affect VSI Throughput?
Throughput depends on feed uniformity, rotor diameter, speed, cascade ratio, power availability, and wear condition of impact parts. Even a well-sized VSI can lose 15–25% capacity if rotor tips wear unevenly.
Rettek designs wear parts for granite, basalt, and recycled concrete so that operators can sustain 300 TPH or more in demanding conditions without frequent shutdowns.
How Does Feed Size Impact Production Rate?
Feed size is one of the strongest drivers of VSI output. Uniform feed below 40–50 mm allows material to accelerate evenly and break efficiently. Oversize feed blocks the rotor ports and can cut capacity by up to half.
With properly scalped feed, many plants achieve 350–400 TPH. Rettek offers rotor tips tailored to different feed bands, reducing fines while keeping output stable.
How Does Rotor Speed Change Output?
Lower tip speeds around 45–55 m/s maximize tonnage with coarser product. Higher speeds up to 80 m/s produce finer, more cubical particles but reduce throughput.
Rettek carbide tips tolerate high RPM without edge rounding, which helps operators maintain output even in sand-making mode where most tips fail early.
What Role Does Material Type Play?
Soft limestone flows easily through a VSI, while basalt and quartz demand more energy and cause heavy wear. This difference alone can shift production from 500 TPH down to 150 TPH.
| Material | Typical Work Index | Usual Capacity Range |
|---|---|---|
| Limestone | Low | 400–500 TPH |
| Granite | Medium | 250–350 TPH |
| Basalt | High | 150–250 TPH |
Rettek carbide inserts are engineered for high-abrasion rock, extending service life and helping maintain consistent capacity.
Rettek Expert Views
“Many operators underestimate how quickly worn rotor tips reduce impact energy. Our in-house alloy preparation and vacuum sintering allow Rettek to produce carbide tips that keep sharp edges far longer in granite and basalt. In real sites we see 25–35% longer wear cycles, which means fewer shutdowns and more stable daily output. For most customers this alone justifies upgrading wear parts, because every hour of unplanned downtime costs far more than premium carbide components.”
Also check:
What Is a Vertical Shaft Impactor and How Does It Work?
What are the main parts of a vertical shaft impactor?
Which Crusher Is Better for Sand Making: VSI or Cone?
How Can VSI Improve M-Sand Quality?
How Much Can a VSI Produce Per Hour?
Where to Buy VSI Crusher Wear Parts?
How Much Power Do VSIs Consume?
Most VSIs consume between 2.2 and 2.8 kWh per ton. A plant running at 300 TPH often draws 200–250 kW depending on speed and circuit design.
Using balanced rotors and low-friction carbide wear parts from Rettek reduces power losses caused by vibration and slippage.
How to Optimize VSI for Maximum Output?
Maximum output comes from uniform feed, correct rotor speed, 15–25% cascade ratio, and timely replacement of worn parts. Operators should monitor amp draw, vibration, and product gradation daily.
Rettek supplies matched rotor tip kits and brazed assemblies that install quickly and keep balance within tolerance, allowing plants to push capacity safely without increasing breakdown risk.
Conclusion
A well-configured VSI can reliably produce 100–500 TPH. The biggest levers are feed size control, rotor speed management, and wear part quality. Plants that upgrade to premium carbide components from Rettek gain longer wear life, steadier throughput, and lower cost per ton. For operators focused on growth, start with feed preparation, invest in durable rotor tips, and review performance data regularly to unlock the full potential of your VSI.
FAQs
What is the typical VSI output range?
Most mid-size machines run between 250 and 350 TPH with proper feed and speed settings.
Can carbide rotor tips really increase capacity?
Yes, durable tips keep impact energy stable, often improving effective throughput by 20–30%.
How often should VSI rotor tips be replaced?
In abrasive stone, every 500–1,000 hours is common, but Rettek carbide tips often last twice as long.
Is a VSI suitable for manufactured sand?
Yes, VSIs are widely used for cubical sand production in concrete and asphalt plants.
Where are Rettek wear parts produced?
Rettek manufactures all carbide wear parts in Zigong, China with full in-house process control.