Why it’s time to start using your mobile crusher’s telematics system

Your mobile crushing plant is doing more than crushing. It's tracking fuel use, flagging faults, logging production numbers, and sending out real-time updates. Mobile crushers are getting smarter every year, but a lot of that built-in technology is still being underutilized, either because crews don't know it's there or because no one was trained on it. 

The technology itself isn't new, but it has come a long way. Originally introduced in fleet vehicles and larger stationary plant systems, telematics has steadily made its way into mobile equipment. Early systems tracked only basic information — engine hours, location, and some service alerts.

Today's platforms go much deeper. They capture real-time data on fuel burn, throughput, idle time, temperatures, and fault codes, usually accessible from your phone or computer, so that you can check in without setting foot on site. 

In mobile applications, this kind of visibility is crucial. Unlike stationary systems, mobile crushing plants work in constantly changing environments. That variability makes it harder to monitor performance and track issues without being physically on site. Telematics bridges that gap by letting you see what's happening in real time, no matter where you are. You can access the information you need to make better decisions, faster — whether it's adjusting feed rates, scheduling service, or spotting underperformance before it costs you.

If you're not already using your crusher's telematics system, now's the time to start. If you've bought a machine in the past five years, chances are you have access to this data. Nearly all new mobile crushers come standard with telematics hardware already installed. Your dealer can help set up the dashboard, explain how to use it, and customize alerts or reports. 

The data is already being collected. You just need to start putting that data to work. Here are six reasons why you should be using your mobile crushing plant's telematics system.

1. Spot problems before they shut you down

Most telematics systems are designed to do more than just report what's happening. They can predict what's about to go wrong. By constantly monitoring key metrics like hydraulic pressure and engine temperature, these systems can flag early signs of wear or mechanical failure before they become serious problems. Catching these red flags in real time lets you act fast. That might mean scheduling service before a critical part fails or ordering a replacement component before a breakdown brings the entire site to a halt.

2. Optimize fuel use and reduce waste

Fuel is one of the biggest operating costs in mobile crushing. Telematics helps track idle time, engine load, and fuel consumption in real time. This allows operators to adjust their habits and reduce unnecessary idling. Several OEMs now include fuel efficiency dashboards in their mobile apps that make it easy to compare performance day-to-day or job-to-job. Over time, a few minor changes in how the machine is loaded or warmed up can result in noticeable savings.

3. Track production in real time

Crushing is all about keeping materials moving. However, operators sometimes rely on rough estimates or wait until the job's done to measure how much material got processed. That leaves a lot of room for guesswork and missed opportunities to improve. Telematics takes the guesswork out. Most systems can show you exactly how many tonnes per hour you're producing, in real time. You also get trend data that highlights when output dips or spikes throughout the day. That makes it easier to spot inconsistencies and figure out why they're happening. 

4. Get smarter about maintenance

Most maintenance plans follow a set schedule, but machines don't always wear out the same way. Job conditions, material type, and how hard you're running the crusher all make a difference. That's where telematics helps. Instead of relying on a calendar, you can shift to condition-based maintenance. This means your machine tells you when it actually needs service, based on data like filter condition, hydraulic pressure, or temperature spikes. This approach helps you avoid unnecessary service and gives your service techs the data they need to plan ahead.

5. Monitor your fleet anytime, anywhere

If you're running multiple crushers across different job sites, keeping track of everything can be a challenge. Most manufacturers now offer cloud-based dashboards that let you monitor every machine in your fleet, no matter where it is. You can log in from anywhere and instantly see which machines are running, how long they've been operating, and whether they're hitting production targets. This is especially helpful on busy or remote sites where getting updates from operators isn't always easy.

6. Support your sustainability goals

Environmental, social, and governance (ESG) is a framework that helps businesses track and report their impact on the environment, their workers, and the communities they operate in. For many, this includes reducing emissions, cutting fuel use, and improving efficiency. Many systems make it easy with built-in reporting tools that give you a clear picture of how your crusher is performing. You can use that data to calculate emissions per tonne, monitor energy use, and find ways to operate more efficiently.