OPEN-CAST MINING
In surface mining operations, tyres represent one of the highest operating costs after fuel.
Leveraging mining tyre management to reduce costs and emissions
Leading tyre service provider, Kal Tire, and tyre manufacturer, Michelin, recently released a joint white paper outlining how improved mining tyre management can deliver both cost savings and measurable emissions reductions. T he white paper, Unlocking Hidden Synergies: How to Leverage Mining Tyre Management to Deliver Cost Savings and Emission Reductions, explores practical, data-driven strategies that enable mining operators to reduce Scope 1 and Scope 3 emissions while lowering operating costs. These gains can be achieved through extended tyre life, reduced fuel consumption and improved productivity—without the need for major capital investment. According to the authors, mining companies worldwide are facing increasing pressure to meet production targets while contending with rising fuel costs, equipment downtime, and growing regulatory, stakeholder and environmental expectations. Tyre management, they argue, remains a largely untapped opportunity for improvement. In surface mining operations, tyres represent one of the highest operating costs after fuel. They also play a significant role in a mine’s carbon footprint through vehicle fuel consumption (Scope 1 emissions) and value-chain impacts (Scope 3 emissions). “When tyre management is reactive or inconsistent, it often results in premature wear, higher fuel consumption and unnecessary emissions,” the paper notes. “By contrast, proactive and predictive tyre strategies—developed collaboratively with OEMs, tyre manufacturers and service providers—are increasingly using advanced technologies to deliver measurable improvements in cost efficiency, productivity and sustainability.” Cutting operating costs while lowering carbon emissions In open-pit mines, loading and haulage activities account for as much as 50–60% of total operating costs, making tyre preservation and lifecycle management critical to profitability. After fuel, tyres are one of the most expensive consumables. A large mine can use around 900 mining tyres annually, representing millions of dollars in operating expenditure.
Poor tyre management practices— such as underinflation, incorrect tyre selection and inadequate maintenance—can trigger a cascade of inefficiencies, increasing fuel consumption and, in turn, Scope 1 emissions. Michelin’s Life Cycle Assessments show that 70–90% of a mining tyre’s environmental impact occurs during its use phase, largely due to the fuel required to move heavy haul trucks. Crucially, because tyre design and condition directly influence performance, operators have significant control over this emissions source. Kal Tire’s Maple Program, validated by SCS Global Services, enables mine sites to quantify tyre-related emissions and demonstrates how lifecycle strategies— such as tyre repair and retreading—can reduce demand for new tyres and minimise waste and emissions. Miles Rigney, Senior Vice President of Kal Tire’s Mining Tire Group, said: “Smart tyre management delivers dual benefits: reduced operating costs and progress toward emissions and sustainability goals. Mines don’t need to choose one over the other—they can achieve both. As stakeholders
22 MODERN MINING www.modernminingmagazine.co.za | March 2026
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