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.

“This is the first time Africa will see a Sandvik mobile plant built from the ground up on a fully electric track platform,” Jaco Benade, Distributor Manager at Sandvik Rock Processing, says. “It is a gamechanging 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 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. 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 is fitted with the proven CJ412 jaw crusher. This latest generation unit features smart technology for real-time performance monitoring 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.

“This machine consumes about 90% less hydraulic fluid than its predecessors which means lower maintenance costs and a lighter environmental footprint,” Benade explains. “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 training for local service teams. A Sandvik factory technician will also be on site for the installation, guiding both distributor and customer 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.”

Sandvik Rock Processing, in partnership with its southern African distributor, S&R Enterprises, has launched its first dual-powered mobile machine in southern Africa, a tracked Sandvik QA452e triple deck sizing screen with Doublescreen technology. 

Upon its arrival, the machine was immediately dispatched by S&R Enterprises to its owner, a contractor operating on a major dam project in Lesotho, where the machine has already been deployed to produce G2 and G5 material.  

PC Kruger, Business Line Manager Crushing at Sandvik Rock Processing, says the launch of the first Sandvik electric unit in southern Africa is in direct response to the apparent growing appetite for electric mobile crushing and screening solutions in the region. While the technology provides both cost and sustainability benefits, Kruger believes that the major driver in southern Africa to date is largely the need to reduce total cost of ownership. 

“Customers in southern Africa are increasingly pursuing energy efficiency due to the significant financial benefits of reducing energy consumption, which is generally a major operational cost. Hybrid solutions, which can be powered by either diesel or grid electricity, offer significant fuel savings and more versatile operation, with the added benefit of reduced carbon emissions,” says Kruger. 

According to Stephen Smith, MD of S&R Enterprises, the major talking point on the Sandvik QA452e screen is its hybrid “e” drive option, which provides the flexibility to operate in diesel or electric mode for lower operating costs and reduced carbon emissions. Powering the machine using an external electric source can bring several advantages, including lower running costs, extended drivetrain service intervals, reduced onsite emissions and noise levels.

“One of the major benefits of this technology is reduced maintenance costs,” says Smith. “The electric motor drive reduces the need for diesel engine servicing and hydraulic oil, increasing machine availability and reducing costs. In fact, the machine consumes up to 50% less hydraulic oil over 10 000 hours of usage. Consequently, hydraulic service intervals have been increased from 2 000 to 4 000 hours, subject to oil sampling.”

In addition, the standard Sandvik mobile equipment warranty has gone up from the traditional 12 months/1 000 hours to 24 months/3 000 hours, with extended warranty options up to six years, providing the much-needed peace of mind for customers. 

The QA452e features Sandvik’s patented Doublescreen technology for high throughput and efficiency. It is a revolutionary design that utilises two high velocity screen boxes that work independently of each other; the primary screen works as a fines extractor, while the secondary screen operates as a grader. 

“Doublescreen advantages over competing products include greater material control, greater adjustability, increased accuracy and higher screening efficiencies, making this unit ideal for producing massive volumes of high specification products, without compromising on productivity,” says Smith. 

The patented Doublescreen design features three independent 20’ x 5’ (6 m x 1,5 m) screens, each providing a screening area of 9 m³/9,3 m², with the bottom deck being 11% longer for more screen area and fines extraction. Compared to conventional 20’ x 5’ screen boxes, the Doublescreen technology typically outperforms traditional screens by up to 30%. It also allows up to 42 screen angle options due to the two screen boxes. 

“The arrival of the first Sandvik dual-powered machine marks a significant step towards a more sustainable and cost-effective future for the local mobile crushing and screening industry,” concludes Kruger. 

Sandvik Rock Processing is accelerating its growth across Africa by combining an expanded product portfolio with a sharper customer focus – delivering integrated solutions from a single point of contact.

“By bringing together stationary and mobile crushing, vibrating screens, screen media and attachment tools like rock breakers, we can address diverse operational requirements while streamlining customer engagement,” Tarynn Yatras, Vice President Sales Area Africa for Sandvik Rock Processing, says.

A key growth area has been mobile crushing and screening equipment, with demand rising from both mining operations and infrastructure projects. The appointment by Sandvik Rock Processing of South African distributors in 2024 has strengthened service coverage and ensured faster local support. 

“We have focused on bundling recommended spares with each unit and ensuring service capability is available from day one,” Yatras explains. The versatility of mobile units makes them ideal for giving flexible crushing and screening options based on customer needs and enabling rapid on-site crushing solutions for contractors.

Innovation is further driving interest, with the first electric-powered Sandvik mobile crusher scheduled for delivery into Africa later this year. “Electric and hybrid (electric and diesel) units are attractive to operations investing in cleaner electric powered solutions” she says. “They help reduce emissions, reduce total cost of ownership and offer simpler, more efficient maintenance than diesel engines.”

The company has also elevated its approach to attachment tools in mining, making rock breakers a strategic component of its solutions portfolio rather than an ad hoc add-on. These tools are now applied across a range of scenarios – from fixed booms at crusher feeds to mobile in-pit use after blasting.

Supporting this broader offering is a strong technical capability embedded across the lifecycle of the equipment. Dedicated resources focus on training, competence development, process optimisation and customer audits – positioning technical expertise closer to operations. 

“This enables deeper application analysis and more precise solution specification, reducing total cost of ownership,” Yatras says. In one project, for example, Sandvik Rock Processing developed 25 different flow sheets – ultimately meeting the customer’s objectives with four fewer crushers than a competitor proposed, cutting both capital and operating costs.

Engagement with engineering, procurement and construction (EPC) partners on greenfield and brownfield projects is another area of growth, alongside sustained demand in the infrastructure sector. Graduate training initiatives, such as the programme in West Africa, are building a future pipeline of skilled engineers and technicians.

“Across all our territories, we are bringing expertise and infrastructure closer to customers, with service at the heart of our strategy,” Yatras concludes.

By embracing a lifecycle management approach with its customers, Sandvik Rock Processing ensures that its vibrating screens meet production targets at the lowest cost per tonne.

The most effective starting point, says Lomave Sukati, Sandvik Rock Processing’s Business Line Manager Lifecycle Solutions, is for mines to request a full assessment from their OEM partner.

“This allows for a gap analysis to identify opportunities for improvement, so the equipment can be restored to OEM standards in terms of reliability and performance,” explains Sukati. “The customer might also require that operators receive targeted on-the-job training, which helps ensure performance is maintained.”

Sandvik Rock Processing’s assessments include a visual inspection followed by dynamic testing to measure mechanical performance. Any defects or concerns are then detailed in a report to the customer for action.

“Our training empowers a customer’s team to recognise conditions that need early attention, as part of overall lifecycle management to keep equipment well maintained and productive,” she says. “The OEM can’t always be on site to conduct daily checks but operators can be trained to do this and a close working relationship with the OEM ensures there are open lines of communication to report issues.”

Regular inspections allow the remaining wear life of parts and components to be estimated and logged, enabling maintenance and part sourcing to be planned well in advance. This prevents unscheduled downtime and allows maintenance work to be done during planned plant shutdowns.

The performance of the screens is also affected by the changing nature of the ore bodies being mined, which requires constant monitoring – as changing geology could result in more abrasive material being crushed and screened.

“This may call for a different choice of wear materials in the screen panels to achieve the required output and wear life,” she says. “Screens are specified for certain conditions at the start of a project but adjustments invariably need to be made during the equipment’s lifecycle.”

Crushers and screens in the same circuit also impact one another, so mines need to work with OEM specialists who understand this relationship when conducting assessments and making adjustments over time.

“Effective lifecycle management is aimed at achieving the lowest cost per tonne over the life of the screen,” says Sukati. “By focusing on where most screen costs are incurred, mines can quickly identify areas to reduce costs as part of broader efficiency and productivity efforts.”

She emphasises that this is the most direct route to achieving low costs per tonne, especially when done in close collaboration with the OEM. She also highlights the value of formal agreements between mines and OEMs regarding responsibilities for keeping screens functioning optimally.

“These agreements provide clear roles for each party avoiding grey areas that could lead to oversights in monitoring, service delivery or parts availability,” she says. “For mining customers, these agreements are powerful tools to derisk their business by enhancing both equipment performance and reliability.”

This gives mines the confidence that they will meet production targets while gaining better control over operational costs through detailed planning and monitoring. Through its service level agreements, for instance, Sandvik Rock Processing places a team of experts on site who is responsible and accountable for the screens and must report regularly on their condition and performance.

“We can also manage inventory to ensure that necessary wear parts and components are available when required to ensure optimal uptime,” she concludes.

To increase energy efficiency and help reduce the climate footprint of the mining and quarrying sectors, Sandvik Rock Processing is leading the shift to electric mobile crushing and screening equipment. Essentially, by using less energy the industry can save money and operate in a more environmentally responsible way.

Mobile crushing and screening solutions remain prominent comminution solutions in both mining and infrastructure sectors. According to PC Kruger, Business Line Manager – Crushing at Sandvik Rock Processing, these solutions are renowned for their quick setup and deployment times, which makes them ideal for sudden spikes in demand. In addition, he says, as the industry continues to adopt in-pit crushing and conveying practices, mobiles can help do away with costly haulage trucks onsite, while reducing onsite traffic, dust and noise – increasing safety on site. 

Another major attribute of mobile crushing solutions is their energy flexibility – the ability to be powered by electricity, diesel or both. To enhance energy efficiency and sustainability, the move to fully electric mobile crushers and screens has in recent years gathered pace. With its range of stationary and wheeled crushers and screens already 100% electrified, Sandvik Rock Processing has been one of the original equipment manufacturers at the forefront of the electric drive alternative.

“The most recent addition to our tracked electric range of crushers is the Sandvik UJ443E heavy duty jaw crusher. This machine is built on a new, ‘fully electric’ track platform. It features electric final drives and an on-board genset which can be operated more sustainably, either by an external electricity supply, hydrotreated vegetable oil (HVO) or diesel,” explains Kruger. 

Operating the machine connected to the external electric source can bring several advantages including lowering running costs and noise levels, extending drivetrain service intervals and reducing time spent refuelling as well as reducing onsite emissions. Using fully electric track drives and final drives, the unit is said to decrease the use of hydraulic oil on the plant by up to 91%.

The Sandvik UJ443E features a 125 Amp downstream connection which allows customers to operate a downstream plant such as a screener or scalper, providing a decrease in fuel consumption of up to 20% compared to running separate units.

“In addition, our wheeled range of crushers has been made to meet the same high standards as its tracked counterparts, operating at maximum efficiency and designed for high-capacity production. Electrically powered, these units offer lower cost per tonne operation as well as lower emissions, minimising the environmental impact, which speaks directly to the industry’s sustainability drive,” Kruger concludes.

The groundbreaking ACS-s condition monitoring system from Sandvik Rock Processing is a transformative solution designed to deliver real-time insights into the performance and operational health of vibrating screens and feeders. Built for the most demanding operational environments, ACS-s empowers mining and processing operations by enabling early fault detection allowing corrective action to be taken swiftly thereby reducing costly unplanned downtime.

“As screens and feeders operate under constant mechanical, traditional maintenance approaches have relied on visual and auditory inspection – often identifying faults only after serious damage has already occurred,” says Frengelina Mabotja, Business Line Manager -Screening Solutions from Sandvik Rock Processing. “Sandvik’s ACS-s changes the game by constantly monitoring the unique vibration patterns of each machine and identifying even the smallest anomalies before they evolve into major failures.”

The system’s real-time monitoring capabilities detect the first signs of imbalance, abnormal motion, structural fatigue or unusual acoustic signals. With alerts sent directly to a mobile device or central monitoring dashboard, maintenance teams can intervene early, preventing unplanned stoppages, extensive repairs or production losses. As a result, sites benefit from improved equipment uptime, more reliable performance and lower maintenance costs.

Mabotja says that ACS-s integrates seamlessly with SAM, Sandvik’s cloud-based digital service platform, allowing users to scale up condition monitoring across multiple machines and locations. With up to 32 synchronous sensors per installation and customisable sensitivity for each unit, ACS-s offers unmatched scalability and precision. SAM also enables remote support, where Sandvik engineers can access live data to provide expert advice and troubleshooting.

Designed for easy deployment and maximum flexibility, ACS-s uses magnetically mounted energy-harvesting wireless sensors that require no wired power or data connections. Its built-in router and antenna offer connectivity via LAN, 4G/5G or Wi-Fi, while advanced fieldbus protocols ensure compatibility with plant control systems for seamless integration.

“The ACS-s solution gives operators the choice of in-house monitoring or a collaborative model supported by our global network of service professionals,” Mabotja says. Whether on-site or remote, teams can access real-time diagnostics, interpret fault conditions and follow guided steps to restore optimal equipment functionality.

With its robust architecture, user-friendly design and intelligent software integration, Sandvik Rock Processing’s ACS-s marks a new era in proactive machine health management for screening and feeding applications. “It is an innovation that helps the industry work smarter, moving from reactive to predictive maintenance because early detection is the key to early intervention,” Mabotja concludes. 

Sandvik Rock Processing is making it easier than ever for mining operations to cut costs and improve efficiency with its innovative X-change programme. This initiative allows mines to upgrade outdated spiderless and legacy hydrocone crushers with the next-generation Sandvik 800i series cone crushers – and the return on investment can be seen almost immediately.

According to PC Kruger, Business Line Manager – Crushing at Sandvik Rock Processing, the real value lies in how this programme helps operations reduce their total cost of ownership while optimising performance. “By taking advantage of the X-change programme customers can replace older technology with our high-performing Sandvik 800i range at a special price, while also gaining access to warranty support, ramp-up assistance and Sandvik’s advanced digital tools, all of which add up to significant operational savings.”

Kruger explains that customers upgrading through the X-change programme can expect up to 30% improved availability and up to 25% more final product delivered to downstream processes. This enhanced performance is due in large part to the Sandvik 800i’s state-of-the-art automation and robust mechanical design. 

Equipped with the Sandvik ACS-c 5 automation system, the 800i crushers offer rapid liner calibration – completed in just five minutes – helping to reduce downtime and boost productivity. The automation system also includes role-based functionality, guided alarm responses for operators and full access to historical and real-time data for maintenance teams, empowering proactive planning and accurate performance monitoring.

On the mechanical side, the Sandvik 800i series is built for durability and efficiency. It features a direct-drive design that reduces energy loss, a strong unibody structure and top-down maintenance access that simplifies servicing. Other enhancements, such as Constant Liner Performance (CLP) chambers as well as a huge variety of chamber profiles to adapt to every unique application, double-sealed pinion shafts and non-welded bottom shell wear liners with plastic-free fasteners, all contribute to reduced maintenance requirements and longer wear life.

The Sandvik 800i range supports sustainable efficient operations in a wide variety of applications including three-stage crushing circuits, SAG/AG mill pebble crushing, heap leach operations, lump ore processing and integration with HPGR systems. These cone crushers are designed to deliver finer particle sizes, enhancing downstream performance and reducing energy consumption across the board.

Importantly, every Sandvik 800i crusher is fully compatible with SAM by Sandvik, the company’s cloud-based digital assistant. Through SAM, customers can monitor equipment in real time, receive alerts, track performance and order parts – streamlining operations and enhancing decision-making.

Kruger emphasises that the X-change programme is more than an upgrade and is a strategic opportunity for mines under pressure to increase efficiency, reduce energy consumption and extend asset life. With structured pricing, digital support and reliable aftermarket services built in, the programme provides a clear and cost effective pathway to modernising crushing circuits.

“Upgrading to the Sandvik 800i via our X-change programme provides a structured path to improve safety, increase availability and enhance productivity across crushing operations,” Kruger concludes. 

AfriSam has enhanced its Rheebok Quarry operation with the installation of a high-capacity Sandvik CH430 cone crusher from Sandvik Rock Processing. The upgrade ensures reliable safe production with reduced maintenance and a lower carbon footprint.

Located near Malmesbury in the Western Cape, the granite quarry produces a range of materials, including aggregate stone, crusher sand, roadstone and ballast. According to Desmond Jacobs, AfriSam’s Senior Engineer for the Western Cape, this investment aligns with the company’s long-term capital strategy.

The decision to install the Sandvik CH430 was driven by key features such as its hydraulic Hydroset™ system and Automatic Setting Regulation (ASRi) system, both of which enhance performance and streamline maintenance. The Hydroset™ system enables precise automated closed-side setting adjustments, while the ASRi system continuously monitors and optimises crusher performance.

“We appreciate how the Sandvik CH430 minimises operator intervention allowing real-time adjustments to the closed-side setting,” says Jacobs. “This improves product size consistency and quality. The system also tracks key parameters like temperature and pressure, enabling proactive maintenance and reducing unexpected breakdowns.”

Jacobs notes that the new unit has already demonstrated its impact on product quality by reducing oversized material in the feed stream.

“Our initial assessments showed a dramatic reduction in oversize material being sent for secondary crushing,” he says. “This allows us to optimise throughput and potentially eliminate redundant processing steps in the future.”

A crucial factor in selecting the Sandvik CH430 was its compact footprint which closely matched the previous crusher. “As a brownfields project, we had to work within existing site constraints,” Jacobs explains. “Matching the footprint was essential as we had limited time for installation and could not accommodate extensive structural modifications.”

PC Kruger, Business Line Manager for Crushing Solutions at Sandvik Rock Processing, highlights the Sandvik Plant Designer platform which helped optimise the model selection process. Additionally, the energy-efficient crusher, powered by a 132 kW motor, aligns well with AfriSam’s specification, contributing to lower energy costs and reduced carbon emissions.

With a local office and warehouse in Cape Town, Sandvik Rock Processing ensures AfriSam receives prompt technical support, spare parts and plant audits whenever required.

With demand for most commodities – especially for critical minerals – looking strong, mining projects in Africa want to be able to ramp up crushing and screening capacity quickly to make the best of market changes. 

According to Frengelina Mabotja, Business Line Manager Screening Solutions at Sandvik Rock Processing, this means harnessing the power of the latest technologies and digital tools. Mabotja points to the company’s next generation vibrating screens – the SK range – which are designed to meet the highest standards of safety and productivity.

“These screens deliver the lowest total cost of ownership, ensuring that customers achieve maximum uptime and reliability,” she explains. 

The successful integration of screens with crushers is another key aspect of Sandvik Rock Processing’s capability, given its extensive range of solutions across the process flow sheet. This allows multiple opportunities for performance improvement, as the company understands each aspect of the flow sheet. Precise integration between all the elements of the plant makes for optimal efficiency in crushing and screening, says Tarynn Yatras, Vice President of Sales Area Africa at Sandvik Rock Processing. 

“With our depth of expertise and wide range of offerings, we are able to analyse the performance of crushers and screens in relation to each other, not only the behaviour of each,” she says. “This can unlock value in both throughput and recoveries, with performance being further enhanced by remote monitoring using digital technologies.”

The company has also released an exciting range of crushers that are equipped with automation and digital features that facilitate easy integration into a connected system, says PC Kruger, Business Line Manager for Crushing Solutions at Sandvik Rock Processing. The Sandvik 800 Series cone crushers include the hydraulic Hydroset system, which provides safety and setting-adjustment functions. An electric dump valve releases any hazardous objects from the crusher before any serious damage can be caused.

Yatras points to the value of the company’s ‘Connect the Crusher’ initiative, which is digitally connecting its large installed base of crushers around Africa. This allows equipment’s performance to be carefully monitored, providing data to improve and optimise performance and prevent unplanned downtime. 

“Our ever-evolving digital assistant platform SAM is an important element of this technology journey, supporting customers and our own technical teams in achieving operational excellence,” she says. SAM analyses large volumes of performance data using powerful models and algorithms, to make timeous recommendations on which interventions may be necessary.

At a time when quarries and mines seek to optimise their operations and ensure continuous improvement, remote monitoring of crushing data is becoming a crucial element of day-to-day procedures. To meet this growing need, Sandvik Rock Processing is piloting its Remote Monitoring Service (RMS) in Africa.

Crushing operations in Africa can look forward to a new set of digital services following Sandvik Rock Processing’s announcement at Electra Mining Africa 2024 that it is piloting its RMS – a digital system that allows for monitoring of crushing processes remotely. 

“RMS is the latest addition to our suite of existing digital technologies. It complements our ever evolving Automation and Connectivity System (ACS) and SAM by Sandvik cloud-based digital assistant,” explains Nils-Peter Ahlqvist, Sales Support Manager Africa & Latin America – Crushing Division at Sandvik Rock Processing. “RMS translates vast amounts of data acquired from Sandvik crushers into actionable recommendations, reducing operating costs and boosting productivity and sustainability.”

RMS utilises a data-driven study of abnormal behaviour in terms of both crusher performance and health to generate tangible remedial action informed by data. In essence, it provides real-time data that allows customers to anticipate problems before they occur, thus avoiding surprises. 

In addition, the machine visibility RMS provides allows for the replacement of wearing parts before they wear out. Collected data over a period of time will provides insights into parts that are replaced frequently, allowing customers to keep these in stock at all times and avoid unnecessary downtime.

With RMS, mines and quarries can expect increased efficiency within their operations. Continuous analysis of real-time data round-the-clock helps operations get the most out of their equipment, minimising downtime and maximising uptime. Higher uptime translates into higher machine utilisation which, in turn, reduces cost-per-hour. 

“In addition, the data gathered on crusher performance makes optimisation easier with the ultimate goal of enhancing business performance. The alerts, available 24/7, also help reduce high wearing of crusher components, which is detrimental to material consistency and has negative cost implications,” says Ahlqvist. 

Keeping machines running in optimal condition translates into reduced energy consumption which not only results in cost effective operations, but also allows customers to reduce their environmental impact. 

“Energy efficiency and sustainability have over the years become a key part of business decisions for mining companies, especially on the back of growing pressure for the industry to improve its sustainability performance. With RMS, we are bringing yet another set of advanced digital services to help the industry increase efficiency while reducing carbon emissions,” concludes Ahlqvist.