CONCOR’S TRAINING FOCUS BOOSTS VITAL SKILLS FOR MINING

Through its continuous investment in formalised training that delivers recognised qualifications, Concor Mining Services is helping build mining’s skills base from the ground up. 

Serving its blue chip mining customers with a range of contract mining services, the company leverages its recognised position for the benefit of the whole sector, according to Niel Fourie, Group Training Manager at Concor. The company is accredited as a training organisation by both the Mining Qualifications Authority (MQA). 

“This allows us to deliver the quality and level of training that not only ensures our customers a highly productive offering, but also gives employees portable qualifications as they progress their careers through the mining sector,” says Fourie. “The full qualifications, part qualifications and short courses are all vital to driving the minerals sector – which remains a key pillar of our economy. They are also important stepping stones for our employees, who use them to progress and often to study further.”

Among the roles on which the technical training is focused are dump truck operators, excavator and face shovel operators and support plant operators. There is also a focus on developing blasting assistants and foremen with rock breaking qualifications. Offered through the MQA framework, the training includes theoretical and practical elements, and Concor Mining Services ensures new operators become comfortable with site operations by having them work under the supervision of an experienced operators for a period of time. 

“The impact of the training can be clearly seen in our safety and performance indicators, which show employees really benefit from the skills development process,” he says. “We can also confirm the quality of the learning outcomes by the number of our trainees who move on to work for other employers in the sector – including our mining customers.”

He emphasises that Concor Mining Services sees this movement of people as an inevitable aspect of their career development – and the company is proud to have contributed to building the industry’s skills foundation. When a new employee joins the business, their competencies are analysed alongside the new roles they will be required to undertake – and a gap analysis is conducted. The necessary training interventions to fill those gaps are then defined and planned. 

“On this basis, we can develop an individual development plan for that employee, which could look forward one to five years,” he explains. “These individual plans are then aggregated into our Workplace Skills Plan for the business as a whole – which keeps us on track with the demands of the future.”

He points to the significance of a full qualification like the certificate in rock breaking, which enables a person to become an opencast blaster. This, he argues, is as important as a university degree – as it is a requirement for anyone seeking to achieve a blasting ticket. 

“The mining sector is highly regulated, especially in terms of health and safety, so there is no short cut to reach the required levels of awareness and expertise,” he says. “To comply with these regulations, the breadth and depth of knowledge that employees must learn and apply is both intensive and detailed.”

There is also considerable legal liability to be considered, especially in supervisory positions, making Concor Mining Service’s investment in health, safety and related training particularly valuable. The company’s skills matrix is therefore designed to balance employee’s needs for management, technology, operational and technical training. 

“These courses are recognised by the relevant authorities and structures, so they become ‘portable’ assets that raise the overall skill level of the mining sector,” says Fourie. “At the same time, courses we run such as first aid and firefighting add considerable value within our employees’ communities, as they empower individuals to respond to demanding situations outside of the workplace as well.”

The company’s investment in skills over the past five years or so now means that over 95% of surface mining operators employed by the company have earned their industry-recognised certification – enhancing their value to each project and to the safety and productivity of the mining sector more broadly. 

IPR DELIVERS DEPENDABLE DEWATERING SOLUTIONS FOR OPEN PIT MINES

In the challenging environment of open pit mining, efficient water management is crucial to maintaining operations and ensuring the safety and productivity of the site. IPR (Integrated Pump Rental) stands out as a key partner for surface mines, offering customised dewatering solutions designed to meet the specific needs of each site.

Managing director, Lee Vine says by conducting thorough assessments and providing correctly specified equipment, IPR ensures that mines can rely on effective and dependable dewatering systems.

“IPR’s approach begins with a detailed assessment of each individual application. This involves understanding the unique conditions and requirements of the mine such as water volume, pit dimensions and site-specific challenges,” Vine says By doing so, this leading dewatering pump solutions provider can recommend the most appropriate equipment and strategies for dewatering, ensuring optimal performance and cost efficiency.

The backbone of IPR’s dewatering solutions is its extensive range of high-quality dewatering pumps and accessories. This includes the well-known Atlas Copco range of diesel driven and submersible pumps with the company being the Master Distributor across southern Africa for this dependable brand. The company also represents the Toyo range of heavy-duty slurry pumps.

Vine says both pump brands are engineered to handle the demanding conditions of open pit mining, providing robust and reliable performance.

The solution chosen for a specific dewatering project would be dependent on the on-site requirements. As an example, he says that one option would be pontoon-mounted pumps which . allow the pumps to remain operational even as water levels fluctuate. This eliminates the need to frequently relocate the installation as the water level drops, reducing downtime and labour costs.

On the other hand, for mines that require flexibility and mobility, IPR offers skid or trailer mounted dewatering pump sets. These systems can be easily installed at the side of open pits and moved as needed within the mining operation. This mobility ensures that dewatering can be efficiently managed across different areas of the mine, adapting to changing conditions and requirements.

Understanding the financial considerations of mining operations, IPR provides both rental and outright purchase options for its dewatering solutions. Renting dewatering equipment can be an attractive option for mines looking to manage capital expenditure or requiring temporary solutions.

“IPR’s rental services offer mines the flexibility to access the latest technology and equipment without the long term commitment of ownership. However, for mines with ongoing dewatering needs, purchasing equipment outright may be more cost effective in the long run,” Vine says. IPR offers competitive pricing and comprehensive support for purchased equipment, ensuring mines receive the best value for their investment.

IPR’s commitment to its customers extends beyond providing equipment. The company offers comprehensive support services including installation, maintenance and troubleshooting. This ensures that dewatering systems remain operational and effective, minimising downtime and maximising productivity.

“Our expertise in dewatering solutions, combined with our team’s tailored approach to each mining site, makes IPR an invaluable partner for surface mine dewatering projects. By offering a range of reliable equipment, innovative solutions like pontoon mounted pumps and flexible acquisition options, we help mines manage water effectively, ensuring smooth and efficient operations,” Vine concludes.

SPECIALIST MAINTENANCE OF CONVEYORS PAYS DIVIDENDS IN UPTIME

When margins are squeezed by lower commodity prices, mines must secure the productivity and efficiency of key functions like conveyors – and Tru-Trac Rollers can assist in doing just that.

“Turmoil in the mining sector is leading to lay-offs and pressure on capital budgets,” says Guy Fitt, National Sales Manager at Tru-Trac Rollers. “Both these factors can reduce the reliability of conveyor systems, at a time when the mine’s productivity levels can least afford it. As a leading original equipment manufacturer (OEM) in this field, Tru-Trac provides flexible maintenance and support services to solve this dilemma.”

Fitt emphasises that conveyor systems are the life blood of any mine or plant, so it is critical to ensure adequate maintenance or the whole operation’s productivity will suffer. Where mines are under financial pressure, Tru-Trac can step in to take the load off certain personnel, freeing them to focus on other critical areas of the mine.

“We can assume responsibility for a range of tasks from checking and changing idlers to the cleaning of belt scrapers and maintaining belt trackers,” he says. “These are vital to avoid downtime, but can go ignored if mine staff are too thinly spread – with dire consequences for uptime and production.”

Tru-Trac Technical Product Manager Gerhard Strydom notes that mines sometimes even need to do without their usual complement of artisans and assistants during difficult times. The company’s support teams are ideally suited to step in and assist, says Strydom, as they are well trained in general maintenance of conveyor systems while also being familiar with the mining industry.

It is clear that the market recognises the value of Tru-Trac’s support, he points out, as a number of them have been customers for over 12 years. Many of these relationships have evolved into maintenance contracts with a team dedicated to conveyor maintenance on site for a specified time. Fitt explains that the work which these teams perform during these hours, while focused on conveyor maintenance, is not limited to only Tru-Trac’s products, but rather focuses on overall conveyor maintenance, performance and safety.

“The benefit of well trained and experienced conveyor service and maintenance teams ensure that belts are well maintained, and the necessary preventative maintenance work is completed, contributing to our customers’ other related requirements wherever possible,” he says.

As the company’s national footprint has expanded, it has recruited and trained technicians from areas close to the customer base, facilitating the upskilling within local communities. These individuals require comprehensive training to ensure skills and an in-depth knowledge of Tru-Trac products. Training is done either at head office or at the branches.

Tru-Trac’s aim is to improve the efficiency of the customer’s conveyor system, says Strydom, which means giving all aspects of this equipment the attention they deserve. He warns that the conveyors on many mines are only attended to when there is a breakdown.

“While some customers request that we train their staff in equipment maintenance if they have enough personnel, it is increasingly common for mines to keep us on site as the specialist OEM, allowing their artisans to concentrate on core mining activities,” he says.

“The advantage of a maintenance contract is that the mine has the comfort of knowing a specialist is on site, giving this essential system all the necessary attention,” he says. “We conduct regular surveys of belt tonnages, belt speeds and ground conditions, for instance, to check that the trackers and other equipment are performing to our standards.”

It is this ‘extra pair of eyes’ that allows the uptime of conveyor systems to be optimised. Tru-Trac has developed relationships of trust with longstanding customers through its ability to identify issues and bring these to the attention of management. In one instance, the team identified a problem where a customer’s run-of-mine belt was lifting off the structure completely – causing misalignment, loss of product and damage to the belt itself. After reporting the issue, Tru-Trac was able to design, engineer and install a solution to the customer’s satisfaction.

“We have skilled and experienced teams close to customers, who we continuously upskill through our training resources,” says Fitt. “This expertise is available to the mining sector, and has proven to have a marked impact on conveyor uptime and productivity.”

ENGINE AIR FILTER PRE-CLEANERS SAVE COAL MINE ON FILTER COSTS, DOWNTIME

Heavy duty cooling and air conditioning specialist Booyco Engineering has installed the innovative Sy-Klone engine air filter pre-cleaners on two drill rigs at a South African coal mine, allowing the customer to save on the costs of both replacement air filters and operational downtime.

“In dusty mining conditions, engine air filters quickly clog and need replacing,” explains Gordon Postma, Sales Manager at Booyco Engineering. “On this coal mine, the drill rig filters were lasting only two or three days before they needed replacing; the customer really needed a more sustainable and cost effective solution.”

This was provided through the supply and installation of four Sy-Klone Series 9000 engine air filter pre-cleaners – two on each drill rig. This leading technology from the US has been proved over decades, and has been continuously refined and improved.

“The result is that these Sy-Klone engine air filter pre-cleaners can collect and expel 92 to 95% of the ambient dust before it even reaches the engine’s air filter,” says Postma. “The scientific design and robust manufacture of the pre-cleaners – using hard polymer plastics for strength – ensures they need little to no maintenance, and can withstand operating in harsh mining conditions.”

The operating principles of these air pre-cleaners make them remarkably effective, he says. Air enters the underside of the dome design through screened louvers. This prevents any large debris from entering the pre-cleaner which could cause restriction in airflow. Curved particle-accelerator blades push dirt against the sidewall, and strakes – or angled fins – along the interior surface move all heavier-than-air debris towards the ejection slot. This leaves the clean air to continue swirling to the centre of the dome and through to the engine air filter inlet pipe into the engine’s air filter housing through the filter and then into the engine.

“By installing the Sy-Klone engine air filter pre-cleaner, the mine can significantly extend the service life of its engine air filters,” emphasises Postma. “While the savings on the costs of these filters will be important, the real cost to the mine is in drill rig downtime while the filters are changed. The operation will now benefit from better efficiency and productivity due to less maintenance.”

He adds that, by keeping the engine’s air filter cleaner for longer, the pre-cleaner also enhances the performance and fuel efficiency of the engine – as there is less restriction of air moving into the combustion chambers.

“These various benefits add up to a comprehensive solution for the customer, with minimal technical intervention as the pre-cleaners can be readily sized and installed with little disruption to production,” he says.

As a relatively recent addition to Booyco Engineering’s market offering, the Sy-Klone distributorship shows considerable potential in South Africa’s mining sector, as well as in other applications where machinery must operate in high levels of dust. Postma says there is potential for more pre-cleaner installations by this coal mining customer, while a number of other expected installations will soon confirm the product’s efficacy under a range of local conditions.

UNLEASHING THE POWER OF THE ULTIMATE HIGH PERFORMANCE DEWATERING PUMP

Engineered to deliver reliability and efficiency in challenging environment, the next generation Godwin HL270 dewatering pump is now available from Integrated Pump Technology. As a recently appointed Godwin distributor, the company says that this latest model epitomises excellence in the field of fluid handling solutions and addresses the diverse and demanding needs of the African mining industry.

The Godwin HL270 is designed for applications requiring high heads and rapid dewatering, and while being of robust construction features the latest technology ensuring dependable and efficient water management.

One of the standout features of the Godwin HL270 is its powerful performance. The pump boasts an impressive maximum head of 270 metres and a flow rate of up to 200 cubic metres per hour. This capability ensures that even the most extensive and demanding dewatering tasks are handled with ease. The pump’s efficiency translates into reduced operational costs and increased productivity for end-users.

Durability is a hallmark of Godwin diesel-driven pump sets and the HL270 is not an exception. Constructed with high quality materials and designed to withstand the rigours of harsh environments, this pump offers long lasting performance and minimal downtime. The rugged construction and corrosion-resistant components ensure reliable operation in both clean and dirty water applications, making it a versatile choice for a wide range of dewatering needs.

The Godwin HL270 features advanced technology for enhanced performance and ease of use. The pump is equipped with a state-of-the-art control panel, allowing seamless monitoring and operation. The intuitive interface provides real-time data on pump performance, enabling users to make informed decisions and optimise efficiency.

Additionally, the Godwin HL270’s automatic priming system simplifies start-up and operation, reducing the need for manual intervention and ensuring consistent performance.

Environmental sustainability is a key consideration in the design of the Godwin HL270. The pump is engineered for fuel efficiency and low emissions, aligning with both Integrated Pump Technology and Godwin’s commitment to sustainable practices. The HL270’s efficient operation not only reduces fuel consumption but also minimises its environmental footprint, making it an eco-friendly choice for dewatering projects.

As an official Godwin agent in Africa, Integrated Pump Technology is committed to providing above average support to its customers, ensuring they achieve optimal performance and longevity from their dewatering solutions. The company’s team of experienced engineers understand the critical nature of dewatering in mining operations and work closely with its strategic network of distributors to meet all needs.

NEW ENDURON® ORBITAL SCREENS FEATURE ALL-BOLTED CONSTRUCTION FOR LONGER LIFE

Weir, a global leader in innovative mining technology, has launched the all-new ENDURON® Orbital range of vibrating screens which feature an all-bolted construction for longer life. Engineered for sand and aggregate, construction and small tonnage mining operations, the new screens are designed to meet the most demanding of applications.

The all-bolted construction of the screens will significantly improve reliability by eliminating welding in high-stress areas, removing the leading mode of failure in vibrating screens. Locking bolts ensure structural integrity and durability, facilitating easy maintenance with quick replacement of individual components without the need for extensive downtime.

“Weir is excited to bring this revolutionary new screening technology to market. The team has worked hard for the past two years to bring our customers a product that is reliable with the lowest total cost of ownership,” Corné Kleyn, Global Product Manager for Vibrating Screens at Weir says. “Our first screen has been successfully installed and commissioned at a large global customer and we are gaining momentum with more units planned for both the European and North-America markets.”

The ENDURON® Orbital range is available in two screen types: the E series: Elliptical Motion Horizontal Screens and the C series: Circular Motion Inclined Screens. Both screen types are designed with a commitment to innovation and quality, incorporating the latest technologies to deliver exceptional performance in a broad range of sand and aggregate and mining duties.

A wide operating window provides flexibility to adjust screen settings in line with changing applications or feed conditions, without compromising the equipment’s structural integrity and minimising the risk of structural failure related to harmonic resonance.

The modular screen construction ensures that individual components can be easily replaced. Common interchangeable screen parts reduce inventory overflow and simplify maintenance. Both screens are digitally enabled, including our modular exciter technology, which senses and reports on the condition of the exciter. The exciter itself features a bolt-on/bolt-off design, meaning they can be easily changed on site and refurbished in a mechanical workshop.

All ENDURON® products are fully supported by the Weir service network, offering unrivalled service, support and local expertise across the globe. Weir continues to lead the industry in providing cutting-edge, high-performance solutions that are tailored to meet the unique requirements of our customers.

GROWING ROLE FOR CHRYSO ADMIXTURES IN EAST AFRICA’S CONSTRUCTION BOOM

With the construction sector in East Africa seeing an upswing, CHRYSO East Africa has grown its offerings to the market while ensuring its admixture solutions are targeted at local conditions.

According to Graham Dean, CHRYSO’s Business Development Director Eastern Africa, the region’s growing investment in construction projects is evident in countries like Kenya, Tanzania and Uganda. While infrastructure development such as roads and railways are mainly driving this growth in Kenya, it is Tanzania’s mining industry and Uganda’s oil sector which are becoming more significant.

“As a key construction product, concrete uses natural materials which are locally sourced,” says Dean. “This might include cement produced from limestone quarried around Nairobi, pozzolana to modify different cement types or quarried aggregates and crushed sands. To achieve the best results in concrete, it is important to understand the variations in what Mother Nature provides to us as raw materials.”

He highlights that concrete admixtures which have been well proven with materials in South Africa, for instance, may not necessarily perform to the same levels with concrete materials from Kenya. Accommodating these variations has required considerable investment in research and technical facilities in East Africa, to ensure customised admixture solutions.

“To resolve the performance differences between regions, CHRYSO set up a concrete laboratory in Nairobi where we can modify existing formulations,” he explains. “This allows us to design bespoke admixtures for customers, based on their specific requirements and the local materials going into their concrete.”

With its Nairobi office established almost 10 years ago, CHRYSO has developed the locally based experience and infrastructure to become a trusted partner in the concrete space. The company supplies its admixture solutions not only to large construction companies, specifiers and developers, but also to readymix plants, manufacturers of precast products and specialist applicators of decorative concrete.

As the negative environmental impact of sand mining falls under the spotlight in certain East African countries, CHRYSO is also contributing to more responsible practices in the concrete segment.

“The uncontrolled mining of river sand for concrete in many areas has led to concerns at government level, and an expectation that this practice might be banned in future to prevent further damage to the natural environment,” says Dean. “We have promoted our Quad range to raise awareness in the construction industry about alternatives to river sand.”

CHRYSO uses its in-house polymers in the Quad range of products to accommodate the use of challenging sands, including too little or too much fines, swelling clays or irregular shapes. Being able to use lower quality sands can drive down procurement costs, and can also reduce the carbon footprint of a given concrete where these alternative materials are closer to site.

“We have also taken a leading role in the supply of additives to cement producers, with our in-depth understanding of cement production technologies,” says Dean. CHRYSO has been supporting cement producers to reach their sustainability goals, as cement manufacture is a leading contributor to carbon dioxide emissions. The company’s innovations allow more efficient clinker grinding, reducing power consumption in this energy intensive process. 

The additives permit increases in the compressive strength at the initial, mid-term and later ages. The resulting enhanced performance can meet specific market needs such as reducing cement fineness or lowering unit production costs. The clinker factor can also be reduced by using increased levels of supplementary cementitious material (SCMs) while retaining cement performance. CHRYSO additives can be used for the grinding of most cements in all types of grinding systems, including those with ball mills, roll presses, and open and closed circuits, as well as horizontal roller and vertical roller mills.

CHRYSO is able to develop specialised products for customers, to suit their applications. A customer in Mombasa, for instance, needed a solution for the use of coral limestone as a bulking agent in cement production.

“Coral limestone is a notoriously difficult material to blend effectively into cement,” he notes. “Through extensive trials for the customer, CHRYSO East Africa was able to formulate a solution by finetuning one of our products; the result was a solution which overcame the customer’s challenge and is now being regularly used.”

SPECIFY YOUR TRANSFORMER WITH TOTAL COST OF OWNERSHIP IN MIND

Rather like a vehicle, the total cost of running and maintaining a transformer over its lifespan will be considerably higher than its purchase price; these other cost factors therefore deserve close consideration before any purchasing decision is made. 

“The rated power of a transformer is usually among the key determinants of its capital cost, but there are various design differences which will also come into play,” says David Claassen, Managing Director of Trafo Power Solutions. 

To help the purchaser to effectively assess the capital cost, transformer manufacturers need to provide a detailed data sheet indicating required parameters such as losses, windings material and environmental conditions to name a few. . 

“The next main area of costs is operational – in other words, the running and maintenance costs,” explains Claassen. “Running cost is essentially the cost of electricity, measured in kWh. These costs are affected by the efficiency of the transformer. All transformers have both no-load losses and load losses. The monthly cost of electricity for low loss transformers is lower than that of those with higher losses. However, the capital cost of a low loss transformer will be higher due to the design requirements to meet lower losses.” 

Turning to the maintenance costs, he points out that these vary considerably between oil cooled transformers and dry-type transformers – the latter being cooled by air. Oil samples from oil type transformers need to be regularly taken and analysed as this provides valuable insight into the condition of the unit and any possible areas of underperformance.

“These oil checks are similar to taking a blood sample, as the analysis allows the owner to predict the necessary steps to keep the transformer in optimal condition,” he says. “In dry-type transformers, the absence of oil as a coolant significantly reduces the maintenance cost.”

Other important maintenance tasks include testing of a transformer’s instrumentation such as temperature and pressure gauges, as well as relays. Dry-type transformers will tend to have less instrumentation, with a focus on temperature variation and surge protection. On all types of transformers, it is vital to regularly test that the probes are accurately measuring the unit’s temperature. Another basic check is the torque measurement on the termination points. 

“The next big cost factor to consider is the installation cost of the transformer,” he says. “There are regulations that govern where and how transformers are installed, depending on their characteristics – such as their fire hazard level and their potential danger to the environment.”

Oil cooled transformers are, generally speaking, classified as hazardous in terms of their fire risk, so must be located at a safe distance from human activity. Systems need to be in place to both detect and suppress a fire in the transformer, should this occur. There is also a requirement for containment of oil, in case of a leak or rupture – to avoid environmental damage. 

The inherent safety of dry-type transformers means that they can be installed indoors without this added infrastructure. Rated as Class F1 for fire safety, this dry-type technology can even be safely installed in confined spaces. Where an outdoor location is required, a concrete plinth is usually sufficient as a base. 

“When considering the total cost of ownership – in other words, the capital cost plus operational cost plus installation cost – there is a compelling argument in favour of dry-type transformers, particularly for applications of 5MVA and below up to a voltage level of 33kV,” Claassen says. “This argument becomes stronger with the number of transformers present on a single site.”

On a large mining or industrial site, which may have dozens if not hundreds of transformers, it reduces the cost and workload substantially if they are low maintenance dry-type units. As these operations look to become safer and more streamlined, there are great opportunities offered by dry-type transformers, he says. 

As the price of electricity continues to rise, there is also a focus on reducing the energy losses incurred by transformers. This, he explains, highlights why transformer suppliers must be able to quantify the predicted losses over time. 

“By specifying a lower-loss design, a purchaser could calculate whether it is worth spending more upfront on the capital cost, in order to save on losses over the 20 to 30 year lifespan of the transformer,” he concludes. 

AFRISAM’S ‘HEAVY LIFTING’ FOR MAKERS OF CONCRETE PRODUCTS

Manufacturing concrete products is an industry segment that faces its own special demands, and AfriSam’s 90 years of experience allows it to take some of the weight of these challenges off its customers.

“Some of the country’s leading concrete product manufacturers (CPMs) have been our customers for over 40 years,” says Adele Wentzel, Sales Manager Cement Manufacturing Gauteng at AfriSam. “Relationships like these give us real insight into their daily concerns, and how we can add value to their operations.”

With its need for efficient production lines and quick cycle times, the CPM segment relies extensively on AfriSam’s Rapid Hard (52,5R) cement and its High Strength (42,5R) cement. Concrete products need to be removed from moulds as quickly as possible, and in most cases there are stringent demands on quality, finish and strength.

“While many customers have applications that need our ‘Rolls Royce’ product – the Rapid Hard cement – there are also segments where their concrete products are better suited to other classes of cement,” explains Wentzel. “Whatever the application, though, customers rely on the AfriSam service team to ensure they receive the right cement and the optimal mix to achieve the best results.”

Among current priorities in the CPM segment is to reduce energy consumption – as steam curing is generally energy intensive. A key resource for AfriSam customers is its Centre for Product Excellence (CPE), which helps find innovative and cost effective solutions. 

“The CPE’s depth of expertise – backed up by sophisticated testing and laboratory infrastructure – means there are specialists available in the field of concrete products,” she says. “One of our initiatives has been a collaboration with a leading admixture provider, combining our skills and products with theirs to find ways to reduce costs for customers.”

These initiatives include focused interventions for customers to achieve strategic improvements in their operational efficiency, she notes. 

“Our ability to provide these value-adds stems from the trust we’ve built over many years within the CPM segment through sustained relationships,” she emphasises. “Throughout the years, we have practically demonstrated our contribution to customers’ businesses, providing a tangible contribution cementing the necessary trust.”

This trust is a vital foundation for a segment faced with varying levels of loadshedding, as CPMs rely heavily on electricity supply for curing concrete products. 

“With our flexibility, responsiveness and qualified specialist advice, we help customers to manage operational uncertainties while still ensuring the highest quality of product,” she says. 

TRU-TRAC SETS NEW STANDARDS FOR BELT SCALE ACCURACY 

Conveyor belt scales are indispensable components for measuring bulk materials in mining and industrial operations – but their value is compromised if accuracy is poor.

“The ability to measure moving material in real time allows mines to monitor their mass balance and to ensure that the correct volumes are being fed by conveyor into various plant functions, for instance,” says Tinus Ludik, Sales Manager Bulk Materials Handling at Tru-Trac. “Operating under demanding conditions, belt scales must ideally remain not only functional but accurate – which is why we have developed solutions which stand out in terms of quality, repeatability and accuracy.”

Ludik notes that belt scales can also become less accurate over time, so there needs to be regular calibration to ensure that any extreme deviation is quickly rectified. When accuracy errors are high, a plant is prevented from operating at optimal productivity as plant operators can never be sure whether they are overloading critical equipment like mills. 

“To avoid these risks, Tru-Trac’s range of belt scales are designed and manufactured to the highest standards, so operators can be confident of the readings they receive,” he explains. “This allows plants to operate at their highest efficiencies, with reliable data being provided for decision making.”

The company’s offering ranges from its TTR SI-2 single idler belt scale system to the TTR DI-4 dual idler belt scale system, and on to the top of the range TTR FI-4 belt scale system with a four-load cell design. Equipped with high precision load cells and a fully floating weigh frame, the mid-range TTR DI-4 achieves accuracy errors of below 0,25%. It integrates seamlessly with Tru-Trac’s remote monitoring system.

“Our flagship TTR FI-4 system boasts a fully floating pivotless weigh frame and four-load cell design, making it ideal for critical control point applications and high-precision demands,” he explains. “With an achievable accuracy margin under 0,1%, it sets industry standards in metallurgical accounting.”

Every application requires its own assessment and solution, says Ludik, starting with the belt speed. He points out that faster speeds give the belt scale less time to assess the weight on the belt, and it is best to allow at least one second to achieve a reliable reading. The company’s rapidly growing installed base of belt scales includes installations at large plants with up to 150 belts in a single operation. 

Demand has already extended well beyond the borders of South Africa, with Tru-Trac belt scales at work in Namibia, Zimbabwe, Mali and Tanzania – and sales increasing to Zambia, Botswana, Mozambique and Ghana. International distribution of scales in regions such as Southeast Asia is also demonstrating promising demand for the Tru-Trac range of belt scales.

The robust and shock absorbent load cells are locally produced, and Tru-Trac holds extensive stock to ensure quick replacement whenever necessary. The integrator for each unit is well protected within a stainless steel housing for corrosive environments. Enclosures are designed to ingress protection (IP) ratings of 65 or higher to keep out dust and moisture.

“With our focus on quality, we are also excited to be underway with the process of accrediting our belt scales with the South African National Accreditation System (SANAS) through the National Regulator for Compulsory Specifications (NRCS),” he says. 

He emphasises that regular maintenance and calibration is vital, and Tru-Trac offers support to do this, as well as guidance on the steps and intervals. Weekly or fortnightly calibration is advised, and the company provides the necessary training to staff on site wherever required. The well equipped training facility at Tru-Trac’s factory near Pretoria includes an operational 18 m conveyor on which its belt scales are installed. Specialised training is supplied to customers by the company’s experienced team. 

“We have all the communication protocols available, so our belt scales can link to the mine’s PLC or SCADA systems,” he notes. “This allows seamless monitoring of key indicators such as totalised weight, belt speeds, load cell voltages, tonnes per hour and kilograms per metre; the data that can be reflected is also highly customisable according to the customer’s needs.”