MODERN QUARRYING QUARTER 4 | 2025
Modular muscle for small sand producers
Charting the future of milling efficiency
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Weir parts engineered for efficiency
POWERING THE FUTURE OF QUARRYING
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CONTENTS
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Charting the future of milling efficiency. PAGE 16
Alliance optimises blasting with AI-driven insights. PAGE 20
AECI’s booster technology is reframing mining explosives. PAGE 21
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WEIR PARTS ENGINEERED FOR EFFICIENCY Using genuine parts enables Weir customers to achieve higher equipment efficiency and extended lifespan, thanks to ongo- ing enhancements integrated into every component.
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MODULAR MUSCLE FOR SMALL SAND PRODUCERS Small scale sand producers now have a cost effective, reliable and integrated solution to their production needs, taking the guesswork and risk out of daily operations.
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A YEAR OF REINVENTION AND RESILIENCE
A s 2025 draws to a close, it’s clear that South Africa’s quarrying sector has undergone one of its most defining years in the last decade. While the industry has always been characterised by resilience, this year demanded a deeper level of adaptability, strategic thinking, and long-term vision. Persistent power instability, rising input costs, and uneven construction activity continued to weigh heavily on quarrying oper- ations in 2025. Load management - even with the partial easing of load shedding - forced quarries to re-examine energy strategies, invest in backup systems, and optimise production windows. Fuel price fluctuations added financial pressure, amplifying the need for efficiency across drilling, blasting, crushing, and screening processes. Yet, despite these constraints, aggregate demand stabilised.
becoming a core operational skill. Environmental compliance tightened in 2025, and the indus- try responded. Water-recycling systems, low-emission machinery, biodiesel blending trials, and pro- gressive rehabilitation initiatives gained momentum. Community engagement models matured, with more quarries adopting trans- parent reporting frameworks and long-term land-use partnerships. The shift is no longer merely regulatory - customers, investors, and project owners are demanding measurable sustainability out- comes. Operations that invested early in responsible practices now find themselves ahead of the curve. One of the biggest concerns highlighted in 2025 is the widen- ing skills gap. The sector’s senior technical workforce is ageing, while younger entrants remain few. Yet the year also brought encouraging developments: new artisan training cohorts, revitalised learnerships, and targeted bursa- ries supported by industry asso- ciations and OEMs. Importantly, the industry is beginning to view training not as a cost, but as a strategic safeguard. Mergers and acquisition activity increased, particularly among mid- tier producers aiming to secure resources, strengthen logistics, or modernise fleets. Collaboration across value chains, from explo- sives suppliers to equipment OEMs to rehabilitation specialists, intensified as companies sought efficiency gains through partner- ship rather than competition. If 2025 has shown us anything, it is that the quarrying industry is far more dynamic than it appears from the outside. It is modernising, pro- fessionalising, and redefining its role in South Africa’s infrastruc- ture landscape. The challenges were real, but so was the progress - often incremental, sometimes bold, but always forward-moving.
Infrastructure repair, road rehabilitation programmes, and renewed momentum around strategic logistics corridors pro- vided much-needed consistency. Public sector delays remained a challenge, but pockets of growth signalled cautious optimism. Perhaps the most meaningful shift in 2025 was the mainstream- ing of digitalisation. Real-time fleet management systems, predictive maintenance algo- rithms, autonomous drilling trials, and hybrid mobile crushing fleets moved beyond early adopters. Mid-sized and even family-owned quarries began integrating acces- sible digital tools that improved plant utilisation and reduced downtime. Safety technology also advanced significantly: remote monitoring, fatigue-detection systems, and AI-powered compliance checks played a measurable role in lowering incident rates. Data literacy - once peripheral - is now
EDITOR AND PUBLISHER Wilhelm du Plessis quarrying@crown.co.za ADVERTISING Erna Oosthuizen ernao@crown.co.za DESIGN Ano Shumba
CIRCULATION Karen Smith MANAGING DIRECTOR Karen Grant PRINTED BY: Tandym Print
PUBLISHED QUARTERLY BY: Crown Publications P O Box 140
Bedfordview, 2008 Tel: +27 11 622 4770 www.crown.co.za
TOTAL CIRCULATION Q3 2025: 3 927
The views expressed in this publication are not necessarily those of the editor or the publisher.
Wilhelm du Plessis – Editor quarrying@crown.co.za
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MODERN QUARRYING QUARTER 4 | 2025
QC1 + HD
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family of primary belt cleaners deliver industry-leading performance in the most demanding and varied mining environments. QC1 + ™ Cleaners effectively discharge material from the belt while minimizing the carryback that can lead to conveyor system damage. Our patented Continuous Angle Radial Pressure blade-to-belt technology, our long-lasting application-specific urethane blades, and our rugged mainframes ensure superior cleaning power throughout the blade’s service life. Easy to maintain and quick to service, these robust QC1 + ™ Cleaners protect belt components from premature wear and minimize fugitive material issues — keeping your operation running smoothly, safely and more productively.
POWERING THE FUTURE OF QUARRYING
ELB Equipment’s single-minded focus on quality and service helps drive customers’ profitability. E LB Equipment dominates the mobile crushing and screening market, and it’s no accident. The local equipment giant has maintained a single-minded strategy: giving quarry operators access to the best machines money can buy, backed by knowledgeable people and a solid support infrastructure. For more than 30 years the company has worked in partnership with global crushing and screening manufacturer Powerscreen to provide solutions that are tailored for the local market. In South Africa - and throughout the southern African region - uptime matters above almost everything else. Considering that production targets dictate productivity which in-turn dictates profitability it is clear that stable outputs are essential and require reliable machines able to work the back-breaking hours around the clock. The distribution agreement between the customer-centric ELB Equipment with the world’s most highly regarded manufacturer is a match made in heaven and the reason why more quarries in the region use Powerscreen than all other brands combined. The machines meet expectations to run long hours, handle unpredictable feed materials and deliver consistent tonnages without faltering and few companies understand this better than ELB Equipment. The 100-year-old local company has supplied and supported screen- ing and crushing plants across the country for decades and the quality of Powerscreen combined with ELB Equipment’s extensive branch network and deep product knowledge provides the right measures to keep quarries running reliably day-in and day-out.
ELB Equipment Divisional Director for mining, Wakefield Harding, says choosing the right screening equipment requires in-depth knowledge that goes beyond just matching capacity to output targets, but rather involves more complex challenges that operators face in the pit. Screening plants must handle sticky feeds with- out blinding, deliver sharp separations, recover saleable fines and adapt to shift- ing geology in order to remain productive over the duration of mining operations. Powerscreen’s technology has been designed to meet local expectations with robust screen boxes, aggressive stroke patterns and models tailored for local quarrying conditions. He explains that the combination of world-class engineering and local technical understanding is what gives Powerscreen its reputation for reliability in Southern Africa. Machines such as the new Chieftain 1700X with its innova- tive triple-deck four-bearing screenbox further refine the formula by allowing the screen direction to be reversed when feed conditions demand it. Likewise, the Premiertrak 450 jaw crusher introduces
Even the best screening equipment is only as good as the support behind it. As a result we have developed one of the strongest service and parts networks in the region that is backed by eight full-service branches and three dedicated parts hubs across South Africa.
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SNAPSHOT
The 100-year-old local company has supplied and supported screening and crushing plants across the country for decades.
While Powerscreen remains the centrepiece of ELB Equipment’s quarrying offering the company has widened its portfolio to deliver more complete pit-to-plant solutions.
Under its “Future Now, Future Next” strategy ELB has added LiuGong’s range of excavators, wheel loaders, dump trucks and other earthmoving equipment.
ELB Equipment Divisional Director for mining, Wakefield Harding.
a substantial step change in crushing capability providing the power required for the hardest rock typically found in southern Africa’s mines and quarries. “These develop- ments reflect our commitment to continuous improvement and on-the-ground involve- ment that ensures these advances are suit- able for local conditions and translate into real productivity gains for local operators.
ELB Equipment has developed one of the strongest service and parts networks in the region that is backed by eight full-service branches and three dedicated parts hubs across South Africa.
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MODERN QUARRYING QUARTER 4 | 2025
solutions. Under its “Future Now, Future Next” strategy ELB has added LiuGong’s range of excavators, wheel loaders, dump trucks and other earthmoving equip- ment. This expansion strengthens its ability to sup- port customers throughout the production chain from extraction to hauling to screening and crushing. The LiuGong partnership brings globally recognised reli- ability and affordability to customers supported by ELB Equipment’s well-established aftersales infrastructure. ELB is ensuring that these new additions meet the same uptime expectations that customers have for Powerscreen. Even with this broadened offering the company’s identity remains in its long-standing partnership with Powerscreen. The relationships built over decades are reflected in the manufacturer’s recognition of ELB Equipment as its Regional Dealer of the Year last year which is a distinction that honours sales performance, service excellence and customer satisfaction. “Our foundation with Powerscreen is stronger than ever. We are committed to helping the next generation of projects succeed and we will continue investing in the people, products and support structures that keep our customers productive. That is our focus today and it will remain our focus for the future,” Wakefield con- cludes. l
“Even the best screening equipment is only as good as the support behind it. As a result we have developed one of the strongest service and parts networks in the region that is backed by eight full-service branches and three dedicated parts hubs across South Africa. We also maintain the largest stockholding of mobile crushing and screening equipment in the country which allows customers to take delivery of machines quickly and avoid the delays that can otherwise cripple their production plans,” says Wakefield. He explains that uptime should remain the founda- tion of a quarry’s operations and that ELB Equipment’s application specialists work directly with quarry managers to ensure machines are correctly specified and integrated into the broader processing circuit. By optimising process flow, adjusting deck configurations and providing operator training the specialists are able to help customers achieve consistent tonnage in an efficient manner with an eye on lowering costs per tonne. They also assist customers with preventative maintenance schedules and structured service agree- ments that provide predictable costs over thousands of operating hours in order to reduce unexpected failures. While Powerscreen remains the centrepiece of ELB Equipment’s quarrying offering the company has wid- ened its portfolio to deliver more complete pit-to-plant
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MODERN QUARRYING QUARTER 4 | 2025
JD - 800E SOOSAN Surface drill rig Drilling Diameter ø65~102mm Drifter 22hp / 17kw Air Flushing 5.5 m 3 / min Drill Steel T38, T45
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Available in three sizes - SMP100, SMP200 and SMP300 - the range delivers production capacities from 40 to 100 tonnes per hour, with scalability for future growth.
Small scale sand producers now have a cost effective, reliable and integrated solution to their production needs, taking the guesswork and risk out of daily operations. Pilot Crushtec has invested its decades of design and engineering experience into a range of dedicated, modular sand-making plants that give users the latest fit-for-purpose technology within a short lead time of just two months. MODULAR MUSCLE FOR SMALL SAND PRODUCERS
or reliability,” Marais explains. “It’s all about packaging the well-known components for the user’s conve- nience and peace-of-mind.” This is central to Pilot Crushtec’s modular approach, ensuring that all components fit seamlessly together and are ready to commis- sion - with minimal site preparation costs. While a concrete base can be beneficial, these modules are skid mounted and designed to work on a flat level compacted surface. There is no need for added platforms, welding or extra items like chutes to be specially fitted on site. “As a leading crushing and screening OEM in South Africa, we have been designing and manufac- turing for more than 35 years, which means we have all the necessary in-house designs and engineering for this range,” Marais explains. “This means that customers don’t have to foot the bill for custom engineer- ing – and this alone will save them on upfront capital expenditure and reduces the risk of budget overruns.” Being built from tried-and-tested well-engineered designs also ensures that these standard plants
A ccording to Francois Marias, Sales and Marketing Director at Pilot Crushtec, many smaller operators tend to make do with second-hand equipment, which is often not ideal for their application. “Many operators put together the components - from crushers and screens to feeders and conveyors - but lose time and money during operations due to inefficiencies and unreliable performance,” Marais says. “Alternatively, if they choose to go with a bespoke plant, tailored
for their purposes, this comes at considerable cost and can take many months to design and manufacture.” The Pilot Crushtec modular sand-making plants reduce risk by delivering a turnkey solution that is purpose-built for sand production. These plants have been designed as a complete ready to run solution. The major advantage lies in their con- venience and cost effectiveness as they offer a fully integrated plant that dramatically reduces site prepara- tion and set-up time. “This makes for fast deployment, without compromising performance
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SNAPSHOT
The Pilot Crushtec modular sand-making plants reduce risk by delivering a turnkey solution that is purpose-built for sand production.
Being built from tried-and-tested well-engineered designs also ensures that these standard plants are well proven in the field.
The smallest in the range is the SMP100 which can produce up to 40 tonnes per hour of minus 5 mm sand with a recirculating load capacity of 85 tph through the rotor.
The major advantage lies in their convenience and cost effectiveness as they offer a fully integrated plant that dramatically reduces site preparation and set-up time.
are well proven in the field. Refined over years to work seamlessly across various applications, they are less likely to experience unex- pected breakdowns or operating inefficiencies. “A standard plant also brings the benefit of having already been debugged and optimised, so you’re starting with a solution that’s less likely to have hidden flaws,” he says. “This also simplifies the mainte- nance and support for the equip- ment, as parts are off-the-shelf and easier to source.” He emphasises that Pilot Crushtec’s established support net- works ensure that customers do not scramble to find parts or fix issues - which can be a risk especially on remote sites. The sand-making plants come in three sizes. The smallest in the range is the SMP100 which can produce up to 40 tonnes per hour of minus 5 mm sand with a recirculat- ing load capacity of 85 tph through the rotor. Next in the range is the SMP200, capable of producing up to 55 tph, while the SMP300 can produce 100 tph.
As a leading crushing and screening OEM in South Africa, we have been designing and manufacturing for more than 35 years, which means we have all the necessary in-house designs and engineering for this range.
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Investing in a turnkey solution like our sand-making plants removes the unknown operational elements for the customer allowing them to make reliable forecasts of their returns and expenses.
“Our modular systems also have the advantage of scalability, which is ideal for those customers that will require increased capacity later,” he says. “Our well-engi- neered modular systems allow you to add units or upgrade without overhauling the whole setup, making it easier to scale as your operation grows.” The sand-making plants are manufactured locally to the highest quality standards at Pilot Crushtec’s modern ISO-accredited facilities in Jet Park, Johannesburg. Marais reiterates that the quality of this new equipment helps customers to mitigate risks that could undermine a project’s viability or threaten their reputation in the market. “Investing in a turnkey solution like our sand-making plants removes the unknown operational elements for the customers allowing them to make reliable forecasts of their returns and expenses,” Marais con- cludes. l
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TERRASOURCE DEAL SUPERCHARGES VALUE FOR ASTEC CUSTOMERS An Astec FT200DF mobile cone crusher is delivering a powerful, efficient crushing performance on site at the South African National Roads Agency’s (SANRAL’s) construction project between Bela Bela and Modimolle in Limpopo.
A stec Industries has completed its acquisition of TerraSource Global (“TSG”). TSG offers renowned, long-established brands that include Gundlach Crushers, Jeffrey Rader, Pennsylvania Crusher Elgin, Tabor Vibratory Screens, Norris Screen, CMI and CSI. This investment delivers enhanced value and expanded solutions for Astec customers around the world, including in South Africa and across the continent. TSG is a provider of precise, industry-leading equipment includ- ing crushers, feeders, separators, sizers, liquid and solid separation, dewatering and waste management solutions. The addition of TSG’s technologies to Astec’s portfolio boosts the group’s capabilities in the aggregates, mining, power generation and industrial minerals sectors. Expanding on the benefits for African customers, Astec chief technology officer Michael Rai Anderson says: “Africa remains a key market for Astec. The integra- tion of TSG equipment will enable us to deliver an even broader range of world-class solutions in the region. Customers gain access to TSG’s premier crushing, feeding and sizing systems, which complement Astec’s existing aggregate and mining solutions.” Anderson adds, “In addition, the acquisition brings new product categories to Astec’s portfolio, including specialised crushing and feeding systems for soft to medium-hard materials. TSG also introduces coal crushing, biomass and industrial material handling solutions that expand Astec’s range beyond traditional aggregates.”
TSG is a provider of precise, industry-leading equipment including crushers, feeders,
separators, sizers, liquid and solid separation, dewatering and waste management solutions.
programmes have been imple- mented for seamless integration and to ensure that Astec’s local teams are fully certified on TSG’s portfolio of technologies. Anderson says that further skills development, service centre expansion and job creation opportunities are expected as demand grows and additional capacity and personnel are needed in the region. “With TSG now part of the Astec family, we are ide- ally positioned to serve as a sin- gle-source provider for all crushing, screening, feeding and material handling solutions across Africa. We will ensure that customers have access to the best global solutions with local support.” l
With TSG products, now fully backed by Astec South Africa’s established infrastructure for sales, service and spare parts, customers will enjoy improved local support, Anderson notes. “The local availability of compo- nents and technical expertise enables faster turnaround and continuous operations, ensuring reduced lead times and increased uptime. The enhanced engineering collaboration means that custom- ers will benefit from the combined R&D and technical innovation of both companies.” With Astec South Africa serving as the regional hub for all TSG sales, service and support, training
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MODERN QUARRYING QUARTER 4 | 2025
Weir works closely with their customers to do formal assessments to reduce operating costs.
WEIR PARTS ENGINEERED FOR EFFICIENCY
Using genuine parts enables Weir customers to achieve higher equipment efficiency and extended lifespan, thanks to ongoing enhancements integrated into every component.
“W ith our
solely on the purchase price of spare parts. “Our global studies show that the capital cost of a pump and spare parts represents less than about 10% of its total cost of ownership (TCO) over its lifespan,” says West. “Since energy accounts for nearly 60% of this lifetime cost, opting for a cheaper but less efficient pump can quickly lead to significantly higher operating expenses.” Weir not only guarantees that its spare parts meet world class design and manufacturing standards, but also fine-tunes consumption and operational costs. West says that this is done through correct equipment selection as well as on-site their performance to help customers reduce energy
continuous investment in research and development,
along with our commitment to quality design and manufacturing, we ensure that customers benefit from improved energy efficiency and longer-lasting spare parts,” says John West, Regional Manager Slurry Aftermarket at Weir. “In many cases, replacing an old generation part with a newly designed one actually enhances the overall performance and efficiency of the equipment.” West highlights that energy consumption represents an ongoing and significant portion of a pump’s total lifecycle costs, yet many users remain focused
John West, Regional Manager Slurry Aftermarket at Weir.
process fault finding. “In many non-OEM supplied pumps, manufacturing standards are not adhered to, which also presents potential safety risks to the customer,” he says. “The OEM part incorporates all of
MODERN QUARRYING QUARTER 4 | 2025 12
and unplanned production downtime. However, a growing number of customers are adopting a TCO approach, leveraging Weir’s technical studies to identify more effective ways to reduce long-term operational expenses. “Many of our larger customers ask us to carry out formal assessments to help reduce the operating costs of specific equipment,” West explains. “In many cases, we collaborate directly with their dedicated reliability engineers. For smaller companies without such specialised roles, we step in with our expertise and insights to help lower running costs while enhancing both production efficiency and safety.” One such example was a tailings recovery plant in South Africa, where profitability was closely tied to controlling operational costs. The plant’s owners sought to reduce their total equipment ownership costs by cutting downtime and energy usage. After discovering that replicator parts on the wet end of their Envirotech® Alpha D-Frame pumps were lasting only two months, Weir recommended upgrading to its Wear Resistance Technology - WRT® impeller and throatbush for improved durability and performance. “These WRT parts are a great example of how advanced materials and enhanced hydraulic design can significantly improve efficiency, net positive suction head (NPSH) performance and wear life,” he says. “In this particular application, the OEM parts lasted twice as long, reduced power consumption by drawing lower amperage and delivered a higher head.” West notes that Weir also provided a service technician to support the installation of the upgraded parts and deliver training on general maintenance. This collaboration with the OEM not only ensured proper implementation but also helped enhance the plant’s skill base, contributing to improved equipment longevity and reliability. “The efficiency benefits of OEM parts are even more significant in remote operations powered by diesel generators, where grid energy is unavailable,” he notes. “In such cases, the high cost of energy can be substantially lowered by ensuring all equipment operates at peak efficiency.” Power consumption directly correlates with carbon emissions, which mining companies are increasingly required to reduce to meet their corporate sustainability targets, further underscoring the environmental value of using high- quality OEM parts. l
Original Weir parts boost the equipment’s production capabilities and support smooth operation of the plant.
SNAPSHOT
The original parts also boost the equipment’s production capabilities, supporting smooth operation and maximising uptime.
In many cases, replacing an old generation part with a newly designed one actually enhances the overall performance and efficiency of the equipment.
The efficiency benefits of OEM parts are even more significant in remote operations powered by diesel generators, where grid energy is unavailable.
OEM parts incorporate all of Weir’s latest technological advancements, enhancing efficiency, optimising hydraulics and extending wear life.
our latest technological advancements; enhancing efficiency, optimising hydraulics and extending wear life,” he says. Precisely engineered to fit perfectly, the original parts also boost the equipment’s production capabilities, supporting smooth operation and maximising uptime. “The extended service intervals our parts provide contribute directly to the overall efficiency and profitability of our customers’ operations,” he explains. “They also help minimise the risk of unplanned downtime due to premature component failure.” He points out that users who source non-genuine replacement parts often overlook the significant costs associated with emergency repairs
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The Sandvik UJ443E heavy jaw crushing plant demonstrates the latest fully electric track platform technology now being adopted by the global mining and aggregates sectors.
The African mining and aggregate industries are marking a major milestone with the arrival of the first fully electric Sandvik mobile crushing plant on the continent. Sold through Sandvik Rock Processing distributor, S&R Enterprises, the Sandvik UJ443E heavy jaw crushing plant has already been sold into the market, with significant interest building as the sector accelerates its move towards lower carbon, more cost effective operations. AFRICA’S FIRST ELECTRIC SANDVIK CRUSHER ARRIVES “T his is the first time Africa will see a Sandvik mobile plant built from the
Benade notes that where reliable grid electricity is available, operators can also benefit from extended drivetrain service intervals, leading to reduced downtime and lower lifecycle costs. Proven technology, new platform Built on a fully electric track platform, the Sandvik UJ443E
quieter operation. Where grid power is not available, it can switch to diesel or renewable biofuels such as hydrotreated vegetable oil (HVO).” By offering multiple energy pathways, the Sandvik UJ443E allows customers to adapt to site-specific conditions while preparing for the broader shift towards electrification in mining, quarrying and construction.
ground up on a fully electric track platform,” Jaco Benade, Distributor Manager at Sandvik Rock Processing, says. “It is a game-changing development that helps customers cut operating costs while advancing their sustainability goals.” Benade says the introduction of the fully electric mobile crushing plant is a step change in efficiency and sustainability. “A key differentiator of the Sandvik UJ443E is its energy flexibility,” he explains. “The unit can operate directly from the electrical grid, bringing customers considerable savings through reduced fuel costs, lower emissions and
This machine consumes about 90% less hydraulic fluid than its predecessors which means lower maintenance costs and a lighter environmental footprint.
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is fitted with the proven CJ412 jaw crusher. This latest generation unit features smart technology for real-time performance moni- toring and adjustment as well as an unblock facility that improves safety and reduces downtime. Other innovations include three- speed electric tracks for precise movement, a redesigned feed station with hydraulic tilt access for easier maintenance and a downstream 125 amp connection for integrating other electric equipment such as screening plants. It also offers flexible configurations - from a vibrating grizzly feeder for clean rock to an under-screen option for fines removal.” Market preparation and support The first Sandvik UJ443E unit in Africa is already in preparation for delivery. To ensure seamless commissioning, Sandvik Rock Processing and S&R Enterprises have invested in advanced train- ing for local service teams. A Sandvik factory technician will also be on site for the installation, guiding both distributor and cus- tomer teams through the process. “Comprehensive lifecycle support underpins this introduction,” Benade says. “We have ensured that our distribution network is ready with spares, technical expertise and tailored aftermarket packages. The Sandvik My Fleet telematics will further enhance support by enabling remote diagnostics and performance monitoring.” The arrival of the Sandvik UJ443E in Africa signals a turning point in mobile crushing technology on the continent. Customers can now access a solution that not only delivers on productivity but also drives progress toward decarbonisation and reduced operating costs. “This first Sandvik UJ443E mobile crushing plant is just the beginning,” Benade concludes. “With the level of market interest we are seeing, we expect more units to be placed soon - helping reshape the future of mobile crushing in Africa.” l
Designed for lower emissions and operating costs, the Sandvik UJ443E can run directly from the electrical grid or switch to diesel or renewable HVO fuels when required.
The energy-efficient Sandvik UJ443E represents a major step forward in sustainable mobile crushing technology, paving the way for electrified solutions in Africa.
SNAPSHOT
This is the first time Africa will see a Sandvik mobile plant built from the ground up on a fully electric track platform.
Built on a fully electric track platform, the Sandvik UJ443E is fitted with the proven CJ412 jaw crusher.
The arrival of the Sandvik UJ443E in Africa signals a turning point in mobile crushing technology on the continent.
This machine consumes about 90% less hydraulic fluid than its predecessors which means lower maintenance costs and a lighter environmental footprint.
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Vishal Gautam, CEO of Tega Industries Africa opens the conclave discussions.
With a relentless focus on research and development Tega Industries has introduced world-beating technologies to the market that has placed it as a dominant player in the global mill liner and wear solutions market. CHARTING THE FUTURE OF MILLING EFFICIENCY
help you unlock hidden potential in your plant.” He made the case for adopting an Overall Equipment Effectiveness (OEE) framework where underuti- lised assets and inefficiencies are exposed not just at the equipment level but across the value chain. For mines operating on tight margins, small percentage improvements in mill performance translate directly into millions of Rands saved or earned. The call to action was clear that treating mill optimisation as a strategic business lever rather than a maintenance exercise makes more sense. Continuing on the topic, Professor Aubrey Mainza, deputy director of the Centre for Mineral Research, warned that many plant managers continue to run their mills blind. While technology such as variable speed drives and modern discharge designs are available they are often misunderstood or misapplied. He emphasised that volumetric filling – the correct balance of ore, media and water – dictates perfor- mance. Too much or too little filling changes the internal dynamics, altering the number of particles to grinding media contacts and under- mining throughput. Training in measured adjustments is far more valuable than control systems that only protect the mill. Efficiency is not about buying more equipment but about disciplined control of filling, discharge, speed and media, coupled with training
M uch of this success comes from its close customer engagement and a willingness to challenge conventional thinking in mineral processing. This was evident at its industry conclave that was held in Pretoria recently and attracted over 170 attendees from mines across the world, and where a number of speakers provided a clear picture of where
the industry is heading and how smarter milling can deliver measurable gains. Tega Industries Africa CEO, Vishal Gautam, opened the event with a look at the financial case for adopt- ing better methods and equipment. He argued that milling operations have long been obsessed with availability and tonnage but sel- dom translate those metrics into business value. “We are not here just to supply liners we are here to
Tega product manager for milliners, Sumeet Pahl, says the company constantly innovates to find solutions for its customers
MODERN QUARRYING QUARTER 4 | 2025 16
in liner metallurgy, lifter profile and grate configuration must be paired with customer-specific testing to truly deliver results. “Every plant is different and every ore body is different. The answer is not a cat- alogue product but a collaborative design process.” The conclave included talks and case studies from a number of specialists and mine operators including Sandile Nkwanyana of Mintek, Flavio Silva de Moura of Lundin Mining Brazil, Jennifer Giron, ex-senior metallurgist at FQML now working at Tega, as well as Process Manager, Steven Zulu and Vamumusa Manyathi, who is the Business Development Manager of Tega. The combined expertise painted a clear picture which showed that the era of treating mill liners as consum- ables is over. Tega’s approach of marrying business metrics with technical fundamentals and engineering is able to help mines to unlock hidden efficiencies and improve profitability. l
Aubrey Mainza of the Centre for Mineral Research spoke of the importance of balancing all aspects of mills.
operators to think in small, precise corrections. Sumeet Pahi rounded off the session by highlighting how Tega is translat- ing these insights into product innovation. “Discharge systems are too often neglected despite being central to circuit stability. Poor grate design, block- ages or inadequate media can create ‘washing machine’ effects where slurry circulates without exiting the mill, wasting energy and hammering liners.” As a result Tega’s research and development teams have developed optimised discharge designs and wear monitoring tools that not only extend liner life but also stabilise grind conditions. Sumeet explained that innovation
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THINKING OUTSIDE THE EXPLOSIVES BOX
Conditions in Africa are often harsh and unforgiving, creating an environment more hostile to mining than most. When roads end, temperatures soar or plummet, and security risks escalate, extraordinary explosives storage solutions may be needed. By Johan von Landsberg, Technical Manager at Mining and Energy Acuity (MEA).
W hile the management has to adhere to demanding safety and regulatory frameworks. People’s lives and wellbeing, the safety of surrounding communities, project continuity, and the integrity of expensive goods are on the line. However, sometimes tried-and- tested standard storage practices just don’t cut it. Situations aren’t always ideal – some mines have no choice but to operate close to urban centres, while others are located deep in the untamed African bush. Sometimes they’re even located in conflict zones, where explosives African mining landscape can be unpredictable, explosives
like the DRC, central Mozambique, or northern Botswana, transport is often unpredictable and roads vanish into seasonal mud. In such conditions, explosives must often be stored closer to the workface to avoid costly stoppages. Sometimes, especially with large projects, warehouses are warranted. But mostly, containerised or modular magazines, designed for mobility, are the only option. These units can be trucked in, dragged over rough terrain, or even flown in by helicopter. Unlike fixed bunkers, mobile designs must combine portability with full regulatory safety features. MEA has extensive experience in transporting materials through
are highly coveted for non- industrial means. In these types of situations, specialised explosives management solutions providers like Mining and Energy Acuity (MEA) are critical for keeping everything above the line and the supply chain flowing. In these rarer but significant designed to meet the demands of specific conditions under complex environmental and socio-economic circumstances. cases, operators must turn to atypical storage solutions Remote or inaccessible sites For example, the further a project moves from established infra- structure, the harder it is to rely on centralised magazines. In regions
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Temporary or emergency storage
can’t store sensitive explosives in a tin structure facing 45-degree heat, or knee-deep in water. The solution must be engineered to keep conditions within safe thresholds, no matter how hostile the environment outside. That’s why MEA designs magazines that are fit for purpose – reconnoitring sites to select the best location, and engineering drainage systems that safeguard against seasonal downpours. Security risks and conflict zones Security considerations are always front-of-mind when constructing and maintaining explosives storage units. However, the requirements are considerably more demanding in regions plagued by theft, sabo- tage, or armed conflict. Solutions here may include hardened bunkers with multiple access controls, remote monitoring, and integration with military or police security systems. In volatile conditions, explosives may even be co-stored temporarily with state security forces to reduce vulnerability. Mining operations are generally underequipped to uphold these rigorous, expensive, and time intensive safeguards. MEA bridges this gap with portable magazines designed to resist forced entry, featuring locking mechanisms that remain secure even when tampered with.
The mining industry is no stranger to disruption with border closures, port congestion, or labour strikes that halt the movement of explosives at the worst possible time. To prevent project delays, companies some- times establish temporary or emergency storage facilities near worksites. Portable magazines, containerised storage, or adapted facilities can all be utilised, provided they meet safety and regulatory standards. It’s important to stress that, while temporary, these measures are no less rigorous. A mobile magazine still carries the same risks as a permanent one. It must be engineered, inspected, and secured to the same standard, even if it only exists for a matter of weeks. This involves bringing in an experienced explosives solutions partner who will ensure no precautions are missed. Every mine is unique. And while the rules don’t change, the way you apply them sometimes must. The African environment demands a careful touch, adaptability, and some design creativity. Companies like MEA are tasked with ensuring explosives storage becomes one of the strongest links in the supply chain. l
remote bush and erecting fully fit- for-purpose facilities in record time. Harsh climatic conditions Temperature and humidity are also concerns, as extremes can compromise explosives and create serious safety risks. In the Kalahari, heat can destabi- lise emulsions, while in tropical belts, rain and humidity can render ammonium nitrate prills unusable if stored poorly. Containerised magazines therefore need enhanced insulation, double roof sheeting and ventilation units to allow fresh air circulation and temperature stabilisation, and continuous monitoring to ensure explosives remain stable under all conditions. Dust, rain, and salt air can also damage storage units and packaging. To combat this issue, MEA’s designs use corrosion- resistant materials, sealed joints, and drainage to ensure magazines stay safe, dry, and compliant. These interventions are expensive but unavoidable. You
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Omnia Holdings company BME has strengthened its blasting software offering beyond its premium Blastmap™ blast planning platform through a new partnership with technology leader Strayos. This alliance brings together BME’s blasting expertise and Strayos’ advanced image processing and artificial intelligence (AI) capabilities, delivering enhanced functionality, precision, and next-generation software solutions to the mining industry. ALLIANCE OPTIMISES BLASTING WITH AI-DRIVEN INSIGHTS
the best outcome on the bench and downstream.” Customers have access to improved data, allowing them the opportunity to interrogate their benches from the perspective of geology, drilling, blasting, and mill throughput. Hariparsad noted that the benefit extends beyond financial performance to the ESG imperatives of customers – such as the wellbeing of communities and the environment. Cutting edge innovation driving strategic global growth “Automation integration is now possible with AI technologies, where doing more with less has always been the target,” he said. “This has been achieved by pairing AI-enabled technologies with pre- mium blasting solutions.” As a leader in the field of AI, Strayos continually invests and grows in this sector, which aligns with BME’s value proposition of staying ahead of the innovation curve. “This alliance presents an excellent strategic fit between our two companies, with significant growth opportunities through various streams,” concluded Hariparsad. “These avenues include digitisation, digital twinning, AI-technologies, infrastructure optimisation, cost savings, improved efficiency, automation and others, that our customers will reap the benefits from. There is also scope in terms of our technical services and shared resourcing, providing a platform for continual innovation to expedite global growth and strategic expansion initiatives, adding to the excitement this alliance provides.” l
X PLOSMART™, the new AI-enabled suite of software for integrated mine-to-mill solutions from BME will empower mines, quarries and construction companies with geospatial tools and AI-driven modelling across a single data platform, according to Nishen Hariparsad, BME General Manager for Technology and Marketing. “This collaboration marks an important milestone for BME in strengthening our value proposition to customers,” said Hariparsad. “With XPLOSMART™, we empower our customers and partners through streamlined workflows that integrate geospatial, time-series, and visual data with intelligent analytics. The result is powerful predictive insights, post- blast analysis, and optimisation across the mine-to-mill value chain — all while further enhancing safety and reducing risk.” He highlighted that the new system also provides more insight for customers, allowing them to define pain points in their operations, both upstream and downstream of the blasting circuit. With a footprint across over 5 000
sites and growing, the alliance with Strayos brings a proven track record and reputation for quality and a 24/7 customer service support network. Best of both “Our new premium software offer- ing is aligned with BME’s brand identity and reputation, ensuring that we leverage the ‘best of both’ technologies from a symbiotic relationship between BME and Strayos,” he explained. XPLOSMART™, powered by Strayos technology includes 3D photogrammetry, drone fragmentation, rock mass analysis and smart drill analytics, as well as geotechnical analysis and modelling. Hariparsad said that this enhances BME’s offering as a future-fit, mine-to-mill solution with modular and integrated solutions underpinned by AI – extending our capabilities into ore body movement, haul-road intelligence, highwall safety and rock mass AI. “Significant advantages can be gained within the comminution circuit, enabling mine-to-mill benefits to be realised,” he said. “Each blast is designed to achieve
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Global mining audiences at the European Federation of Explosives Engineers (EFEE) conference were presented with an innovation that is shifting the way blasting is conducted worldwide: the elimination of TNT from explosive boosters. AECI’S BOOSTER TECHNOLOGY IS REFRAMING MINING EXPLOSIVES
• On-site or near-site manufacturing opens pathways for local enterprise development and job creation. Nel explains: “By moving away from TNT and PETN, we’re reducing operational risk and open- ing the door to more sustainable and resilient supply chains.” Developing an alternative was only part of the challenge; proving its reliability under field conditions was equally critical. At a coal producer’s South African opencast mines, blast hole temperatures can reach 120 °C, an environment in which conventional TNT-based boosters soften or degrade. The new booster incorporates a thermally resilient shell that maintains structural integrity in hot- hole applications. Laboratory testing was followed by extensive field trials: more than 84 000 units were tested across African sites before full-scale commercial rollout. Since adoption, over 1,8 million boosters have been safely fired without incident. Operational crews also reported strong acceptance of the design, noting practical features such as easy detonator placement and adaptability in varied blast configurations. Nel says the innovation arrives at a critical time for global mining: “Supply chain disruptions, decarbonisation targets, and heightened ESG scrutiny are reshaping procurement and operational practices. By reducing reliance on restricted imported inputs and aligning with climate reporting frameworks, the TNT- free booster demonstrates how explosives technology can evolve in step with these broader pressures. “Importantly, localised manufacturing not only improves flexibility and security of supply, but also creates measurable socioeconomic benefits through job creation and supplier development.” While explosives have historically been viewed through a narrow technical lens, the case presented in Kraków shows how rethinking their composition can have far-reaching effects. From reducing insurance premiums tied to risk exposure, to easing compliance burdens and lowering emissions, booster design now intersects directly with issues of competitiveness and sustainability. “The interest we’ve seen reinforces that precision, safety and measurable return on investment are universal priorities in mining.” l
A gainst a backdrop of tightening supply chains and rising safety expectations, a collaborative case study from South Africa demonstrated how alternative booster formulations are technically viable as well as safer, more sustainable and economically beneficial. The supply of trinitrotoluene (TNT), a cornerstone of traditional booster formulations, has become increasingly constrained. Production is concentrated in regions such as China and Russia and geopolitical instability has placed commercial users in competition with defence sectors. Beyond supply, TNT and pentaerythritol tetranitrate (PETN) carry inherent risks in handling, storage and transportation. The mining industry, long reliant on such materials, has been compelled to re-examine its dependence on volatile global supply chains. Ritzema Nel, General Manager: Mining Explosives - South Africa, AECI Mining Explosives says engineers and scientists at AECI developed a two-component booster that contains no TNT or PETN. The system uses mostly local, inert materials that only become sensitive in their final combined state. The benefits of this approach are enormous: • Non-explosive inputs lower the probability of accidental detonation during shipping or storage • By avoiding UN Class 1 classification, logistics are easier and less costly across air, road, and sea • Local sourcing reduces carbon emissions associated with importing explosives, aligning with stricter climate regulations and ESG commitments
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