This paper presents an analysis methodology applied to data developed using a laser-based tool for assessing wear in gyratory crushers at Highland Valley Copper (HVC). The analysis correlates crushing performance and chamber geometry. As a result of the knowledge developed during this work, an innovative way to evaluate crusher liner profiles was developed and new mantle profiles were designed. Thus, a reformulation of HVC's standard liner management policy was proposed, which could potentially provide savings of 13% in total crusher liner cost and a 15% reduction in liner replacement downtime. (C) 2004 Elsevier Ltd. All rights reserved.