How to calculate your crusher's cost per ton
Cost per ton = total production cost for a period ÷ tons produced in that period. Total cost includes the boulders consumed at their landed cost (with royalty and transport), power, diesel, labour, wear parts and other plant expenses.
What to include in production cost
- Boulders consumed, at landed cost: purchase price plus royalty / pass, transport and unloading.
- Power: electricity units used by the plant × the tariff, plus fixed charges.
- Diesel for the generator, loaders and other plant machines.
- Wages of plant operators, helpers and supervisors.
- Wear parts and repairs: jaw plates, cone liners, VSI tips, screen meshes, belts.
- Drilling and explosives, if you quarry your own boulders.
- Other plant costs: loader / JCB hire, lubricants, consumables.
What to keep out of it
Keep delivery transport to customers, sales commission and office overheads separate. They are real costs, but mixing them in hides how efficiently the plant itself produces, and makes plants hard to compare.
Worked example (illustrative figures)
In one month a plant crushed 10,000 tons of boulders and produced 9,500 tons of M-sand, metal and dust in 200 running hours. Its production costs were:
| Cost head | Amount (₹) |
|---|---|
| Boulders consumed (with royalty and transport) | 6,50,000 |
| Power | 1,80,000 |
| Diesel | 90,000 |
| Wages | 1,20,000 |
| Wear parts and repairs | 60,000 |
| Other | 40,000 |
| Total | 11,40,000 |
The result
Cost per ton = ₹11,40,000 ÷ 9,500 tons = ₹120 per ton.
Yield = output ÷ boulders input × 100 = 9,500 ÷ 10,000 × 100 = 95%.
Tons per hour = output ÷ running hours = 9,500 ÷ 200 = 47.5 TPH. Record stoppage hours as well: a falling TPH with the same running hours usually points to worn parts or feed problems.
Using cost per ton
Compare it month by month and between plants rather than against an industry figure — boulder prices, power tariffs and plant sizes differ too much. Set it against your selling price per ton of each product to see the margin, and watch the biggest heads (usually boulders and power) first.
How RockPro handles it
In RockPro Crusher, each shift's production records running and stoppage hours, boulders in and each product out. Plant expenses, power units and diesel are tagged to the plant, so the cost per ton, yield, tons per hour, production vs sales and plant P&L reports are produced without spreadsheets.
Frequently asked questions
What is the formula for crusher cost per ton?
Total production cost for the period divided by the tons produced in the same period.
What is a good cost per ton for a stone crusher?
It depends on the boulder price, power tariff, plant size and products, so there is no single good figure. Track your own cost per ton every month and between plants, and act when it rises.
How do I calculate crusher yield?
Divide the tons of product made by the tons of boulders fed in, and multiply by 100.
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