A lower purchase price does not necessarily mean a lower wear cost. A liner that needs changing sooner can cost more per ton processed. A simple change-out log makes the comparison visible and records whether a set wore out normally or failed early.
Start with the part cost and measured production. Add labor or other costs only when you can apply the same rules to each set. This is a tracking method, not a price list or a promise of savings.
Define the measures before comparing sets
| Metric | Formula in plain language | Notes |
|---|---|---|
| Life tons | Tons crushed between installation and change-out | Prefer a calibrated plant belt scale or other reliable measurement |
| Life hours | Operating hours on that set | Useful when reliable tonnage is unavailable; exclude idle time consistently |
| Cost per ton | (Part cost + installation labor, if included) ÷ life tons | Use the same currency, cost scope and tonnage unit across sets |
| Cost per hour | The same included costs ÷ life operating hours | An alternative when tons are unknown |
| Failure tag | Wear-out, crack or other recorded reason | Investigate cracks separately rather than averaging them blindly with normal wear-outs |
Freight, downtime and frame damage are real costs. They can be added as optional advanced fields when the site can estimate them consistently. Label the result as part-only or identify every included cost; do not compare unlike totals. Use either metric tons or another defined ton unit consistently, and do not divide by zero or an unknown total.
Blank change-out log
Copy this blank template into a spreadsheet and add one row per set or position. Keep photos and any sensitive cost information in your own controlled records.
| Date | Machine / position | Part + part number | Alloy | Hours | Tons | Cost (local currency) | Failure tag | Notes / photos |
|---|---|---|---|---|---|---|---|---|
Record installation and removal dates in the date field or notes, together with the meter readings used to calculate hours and tons. Note whether the cost is for a single piece or the whole set, and capture feed, setting, operating changes and the reason for removal. If a part is removed early for another maintenance reason, mark it as an incomplete run rather than treating it as a full wear-out.
Fictional worked example
All figures below are fictional and illustrative. They are not customer data, actual GUBT prices, cost bands or expected performance. The calculation includes part cost only, in US dollars per consistently measured ton.
| Set | Alloy | Tons | Part cost (example) | $/ton (example) | Tag |
|---|---|---|---|---|---|
| A | Manganese baseline | 42,000 | $4,200 | $0.100 | Wear-out |
| B | Higher manganese / alternative | 48,000 | $4,600 | $0.096 | Wear-out |
| C | High-chrome trial | 12,000 | $5,100 | $0.425 | Crack with tramp |
For B, $4,600 ÷ 48,000 = approximately $0.0958 per ton, rounded to $0.096. C has the highest example cost per ton because it cracked early. The row does not prove high-chrome is unsuitable in every application: inspect the failed part, feed and tramp controls before choosing the next trial. The HSI material matrix provides an application-specific example of that tradeoff.
Run a fair alloy trial
- Record the baseline on the same machine and position, with part identity, set scope, cost basis and removal reason.
- Where practical, keep feed, settings and operating conditions comparable. Record changes that cannot be controlled.
- Agree the material, geometry and inspection requirements before installation. Run at least one complete set when safe and appropriate; stop early if a failure or maintenance limit requires it.
- Record actual operating hours and measured tons through removal, then calculate cost on the same basis. Keep cracked or incomplete runs visible.
- Review multiple comparable sets where practical. One result is a useful signal, but varying feed and a single failure can make it inconclusive.
For selection inputs rather than another cost assumption, see the cone liner RFQ guide and jaw manganese grade guide. The right alloy depends on the part and duty. Plan a trial around tooling, quantity and inspection using the casting MOQ and lead-time guide.
RFQ for a measured trial
| Field | Send |
|---|---|
| Identity | Part number or machine model and position for model match |
| Current log | Last 2–3 sets from the blank log, desensitized where available |
| Goal | Longer life, fewer cracks, lower cost per ton or another measurable target |
| Constraints | Tramp risk, chamber and feed conditions |
| Quantity | Trial set or fleet quantity, with the pieces in each set |
Share only the cost data you are comfortable providing. If you omit costs, wear hours, tons, failure photos and feed conditions can still help frame the technical review.
Related guides
FAQ
Should I track hours or tons?
Tons are useful for comparing wear cost against output. Use operating hours when tonnage is unreliable, and avoid comparing $/hour directly with $/ton.
Should installation labor be included?
Include it if you can measure it consistently. Clearly label part-only and part-plus-labor results so they are not mixed.
How many sets are needed before judging an alloy?
There is no universal number. Start with at least one complete set when safe, then compare additional sets where practical and review changes in feed and conditions before drawing a conclusion.
What if the scale is inaccurate?
Check and calibrate it where possible. Flag estimated tonnage and its basis; if comparable tonnage is unavailable, use operating hours and avoid presenting estimates as precise $/ton results.
Can dealers use the same log?
Yes. A dealer can track part numbers, quantities and returns, while an end user adds operating conditions, measured output and failure evidence. Agree what information may be shared.
Must I disclose actual costs to request a trial?
No. You can discuss fit and wear evidence without publishing customer costs. Share commercial details privately only when needed for the quotation and under agreed handling terms.
For a trial quotation, email info@gubtcasting.com or use the contact form. Send the part number or model-match details and a desensitized wear history for GUBT to review.
