40:1
Reduction ratio
The VC-100 Crusher Mill replaces a cone crusher and ball/rod mill with one integrated unit — fracturing ore along its natural micro-cracks at just 2.5 kWh/t. We own, operate, and maintain it at your site. You pay per tonne.
The VC-100 is a continuous hydraulic-fracture crusher mill. An adjustable, counterweighted rotating club fractures ore on its micro-cracks — using vibrational kinetic energy rather than compression — to liberate precious ore metals and produce fine cubical particles in a single pass.
A patented process. Ore is fractured along natural micro-cracks by kinetic vibrational energy, creating chains of particle-to-particle impulse forces for maximum liberation.
Real-time oil pressure, tonnage per minute / hour / month / year, and exception messages explaining any stoppage — delivered to a mobile phone app.
Ceases automatically if oil pressure is out of range or feed runs out, and restarts under load — eliminating conventional mill clearance delays.
Side windows enable suction extraction of ultra-fine particles at 75 microns, lifting recovery and effective reduction ratio — and allowing access if tramp metal enters.
Twelve rubber shock-absorbing footings substantially eliminate site vibration, mounting on a compact concrete slab with no heavy civil foundation required.
Accepts up to 10% moisture for dust suppression — more than double the 4% limit of conventional crushers — with zero clogging on wet or damp ROM feed.
A conventional circuit runs three separate machines and 500-550 kW to reach a comparable product. The VC-100 plant replaces the secondary and tertiary circuits with a single unit.
| Factor | Conventional circuit | VC-100 plant |
|---|---|---|
| Machines required | 3 separate crushing & milling units | 1 unit only |
| Bond Work Index | 20 – 23 | 20 – 23 |
| Feed material | −100 mm | −100 mm |
| Conveyors | Multiple return conveyors | No return conveyors needed |
| Throughput | 100 tph | 100 tph |
| Output | P100 (−5 mm) | P80 (−2.5 mm) or P100 (−5 mm) |
| Total installed power | ~500-550 kW | ~220 kW (50-70% savings; depending on ore body & equipment) |
| Solar option | Costly initial setup | Available |
| Energy per tonne | 4.75 – 5.5 kWh/t (milling) | 2.5 kWh/t (full circuit, 380 V VSD) |
| Reduction ratio | 5 – 8:1 per machine | 40:1 single pass |
| Operators required | Multiple (one per machine) | Single operator |
| Moisture tolerance | Max 4% | Up to 10% |
| Noise level | High — industrial | Less than 85 dB |
| Remote monitoring | Manual / SCADA | Live mobile phone app |
The micro-crack fracturing process is effective across a wide range of ores — particularly for precious-metal and diamond liberation — while its throughput and energy profile suit aggregate production.
Accepts copper ROM ore up to 100mm and delivers product at 60+ tonnes per hour. Micro-crack liberation improves concentrate quality and downstream recovery.
Tested on quartzite at Bond Work Index 23, including Merensky and UG2 reef. Fracturing on the micro-cracks liberates gold and platinum more efficiently than compression crushers.
Vibration kinetic energy fractures kimberlite along natural micro-cracks without compressing or damaging the diamonds trapped inside.
Produces -100mm to 19mm and -6mm predominantly cubical aggregate — a desirable shape spec for road construction and civil engineering.
The VC-100 is not prototype technology. It has been field-tested for more than three years across aggregate production, precious-metal ore processing and high Bond Work Index quartzite.
Road-contract application producing -100mm to 19mm and -6mm crushed aggregate in a demanding continuous-production environment.
Tested on quartzite ore at Bond Work Index 23, including Merensky and UG2 reef, confirming superior gold liberation versus conventional circuits.
Validated mineral-liberation performance — fracturing along micro-crack planes increases gold exposure and improves downstream recovery.
Vibro Crushing deploys and operates VC-100 Crusher Mills at your site under a long-term Take-or-Pay Service Level Agreement. World-class capability without the capital outlay, maintenance burden or operational complexity of ownership.
A compact two-machine plant on a minimal concrete slab — no heavy civil foundation.
Vibro Crushing carries the equipment, spares and operating responsibility.
Tonnage, oil pressure and exceptions stream to your portal and mobile app in real time.
A transparent Take-or-Pay rate on throughput — capability without capital.
Three separate operations put the VC-100 through independent test work — on PGM reef, gold rock-dump and ferrochrome slag. Each measured the same things: how much finer the product is, and how much less power it takes, against the cone-and-mill circuits they run today.
The VC-100 fractured both Merensky and UG2 reef to a P80 of 1.0mm in a single pass — against 12mm from a secondary cone at a 10mm setting. Unlike a cone crusher, throughput climbs and power-per-tonne falls as drive speed rises. Simulation showed VC-100 feed needs only one ball-milling stage where the cone circuit needs two.
| Drive speed | Throughput | Power |
|---|---|---|
| 400 rpm | ~4.2 tph | ~8.3 kWh/t |
| 800 rpm | ~8.7 tph | ~3.6 kWh/t |
| 1100 rpm | ~9.6 tph | ~2.9 kWh/t |
| 1300 rpm | ~11.4 tph | ~2.4 kWh/t |
Throughput/power values read from the test graphs (approximate). A typical PGM 2–3 stage cone circuit uses 8–14 kWh/t.
Run-of-dump feed at a P80 of 75mm was reduced to a crusher product averaging P80 6.5mm — with 40% already finer than 1.0mm — then carried through the rod mill to a P80 of 1.5mm. Four separate test runs tracked tightly, confirming consistent, repeatable reduction.
| Stage | Result |
|---|---|
| Crusher feed | P80 75mm |
| VC-100 product | P80 6.5mm |
| … 40% finer than | 1.0mm |
| Rod-mill product | P80 1.5mm |
Averaged across four test runs (good run-to-run correlation).
On run-of-dump ferrochrome slag, raising the VC-100 drive frequency above 30 Hz drove markedly finer product. At 45 Hz nearly half the product passed 500µm — against a coarse rod-mill feed — and the lab confirmed the result fit the intended circuit design.
| % passing | 30 Hz | 40 Hz | 45 Hz |
|---|---|---|---|
| −5 mm | 88% | 98% | 96% |
| −1.4 mm | 56% | 77% | 70% |
| −500 µm | 30% | 45% | 45% |
Cumulative passing, recalculated from the lab fraction table.
Test work was carried out by independent operations on the technology now produced as the VC-100 Crusher Mill (the pilot units were designated the “Chameleon” crusher-mill). Figures are drawn from the original test reports; operations are identified by commodity rather than by name. Full digitised reports available on request.
From the first VC-100 built in South Africa to live material-output trials across multiple mining sites — here is the machine at work, crushing real ore and producing fine, cubical product.