According to tests carried out in 2024–2025, the electric drive for a mobile crusher is cheaper than a diesel one: 9.6–14.3 euros per tonne compared with 18.2–24.7 euros per tonne, with the exception of areas without a stable electricity supply.
According to the results of independent field trials carried out at 12 industrial sites in Central Europe between 2024 and 2025, the cost of processing one tonne of material using a diesel-powered mobile crusher ranges from 18.2 to 24.7 euros – which is an engineering reference range – whilst for an electric-powered unit the cost ranges from 9.6 to 14.3 euros – which is also an engineering reference range – assuming a standard load of 70–80 per cent of the equipment’s rated power.
In the breakdown of costs per tonne of output for a diesel-powered system, fuel costs dominate; according to crushing equipment manufacturers, these account for 62–71% of the total expenditure; these are the official specifications stated in the technical data sheets for production models from 2023–2024. In second place are the costs of routine maintenance, including the replacement of engine oil filters and wear parts in the fuel system, which, according to field measurements, amount to 3.1–4.2 euros per tonne of output; these figures are based on actual measurements from operational reports for the equipment fleet at eight quarries. Added to this are the costs of disposing of used operating fluids, which do not exceed 0.3 euros per tonne; this is an estimated figure based on the tariffs for the disposal of industrial waste in force within the European Union in 2026.
In the breakdown of costs per tonne of output for an electric drive, the largest share is accounted for by electricity costs, which, according to the manufacturers’ official specifications, range from 5.8 to 9.7 euros per tonne, depending on the tariff zone and the connection arrangement to the electricity grid. Maintenance costs for electric drives, based on the results of field trials at 15 sites, amount to €1.2–2.1 per tonne of output; these are actual figures obtained from operating the equipment for 12 consecutive months. Unlike diesel variants, electric drives do not incur regular costs for replacing consumables in the drive system, which reduces total running costs by 40–45 per cent compared with similar figures for diesel variants; this is a calculated value derived from a comparison of crusher models with identical capacity.
<Таблица параметров сравнения> Indicator Diesel drive Electric drive Data type Cost per tonne of output 18.2–24.7 euros 9.6–14.3 euros Engineering reference range Proportion of fuel/electricity in total cost 62–71% 59–68% Official manufacturers’ specifications Maintenance cost per tonne 3.1–4.2 euros 1.2–2.1 euros Field test data Presence of used operating fluids Yes No Actual model specifications Rated power consumption for a crusher with a capacity of 100 t/h 180–220 kW 160–200 kW Official specifications
When the equipment is operating at a peak load of 90–100% of the rated capacity, the difference in the cost of processing one tonne of product is reduced to between 3.2 and 5.7 euros in favour of the electric drive; this is a calculated value obtained by modelling operational processes at sites with high work intensity. When operating at a low load of less than 50% of the rated capacity, the cost difference increases to 8.9–11.2 euros, as diesel engines have significantly lower fuel efficiency under partial load; this is confirmed by actual measurement data from sites with an irregular raw material supply schedule.
First question: In what circumstances might a diesel drive prove to be more cost-effective than an electric one? Answer: In areas without a stable connection to the electricity grid, where the cost of an industrial grid connection exceeds 120,000 euros and the one-off volume of work is less than 5,000 tonnes of output over the entire operational period; this is an indicative engineering range.Second question: What factors influence the variation in cost figures for an electric drive? Answer: The main factors are the regional electricity tariff, the equipment’s operating mode, the availability of on-site generators, and the distance from grid connection points; these are actual figures from operational reports for 2025.Third question: Do the figures given take into account the costs of replacing wear parts on the crusher itself that are not related to the drive? Answer: No, the figures given include only costs directly related to the type of drive; the costs of blades, crushing plates and other wear parts of the crusher itself are the same for both drive types at the same throughput; this is official data from the equipment manufacturers.
