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.

Sandvik Rock Processing customers in the Southern African aggregate and construction industry can look forward to a new era following the appointment of a dedicated distributor, S&R Enterprises, to look after their interests in both the stationary and mobile crushing and screening equipment segments. 

While the distribution agreement is for Southern Africa, initial focus will be on South Africa. In a 24 month staged approach S&R Enterprises will establish its regional footprint, starting with branches in South Africa, and eventually in Botswana and Namibia. 

Led by Managing Director Stephen Smith, S&R Enterprises was established in January 2012, initially with a special focus on aftermarket parts and eventually refurbishing of old mobile crushing and screening equipment. 

With 20 years of experience working with Sandvik Rock Processing and other leading crushing and screening equipment, Smith and his team have built a solid reputation across the mining, quarrying, construction, demolition and agricultural sectors, not only in South Africa, but in Africa at large. 

“We have always been aware of the Sandvik build quality, and that is why we are excited to embark on this partnership to support quarrying and construction customers’ growth aspirations through dedicated support that speaks directly to their operational needs. Our focus is on the small to medium sized stationary and mobile equipment in the 100 to 200 tonnes per hour (tph) size range,” says Smith.

S&R Enterprises, says Smith, has a three-pronged approach to providing unparalleled support to its customers. This comprises an aggressive wear and spare parts pricing strategy, investment in the right machine inventory and a strong aftermarket regime in general – which will be key to clawing back significant market share for Sandvik Rock Processing in the aggregate and construction sector. 

“At the core of our strategy is to get the pricing of our wear and spare parts in line with market expectations. We are working closely with Sandvik Rock Processing to get this alignment right. We strongly believe that this is the first major step in getting the Sandvik brand back to the top, where it rightfully belongs. We commend the Sandvik Rock Processing team, led by Tarynn Yatras, Vice President – Sales Area Africa, for the collaborative effort in this venture,” concludes Smith.

Among the attractions of the Sandvik Digital Assistant (SAM) is that it delivers value to everyone in the crushing and screening value chain, raising the game for forward-looking mines.

Recently launched into Africa at the Electra Mining Africa exhibition in Johannesburg, SAM’s reception among large and small players on the continent has been overwhelmingly positive, according to Ali Jumaa, Digital Product Manager for Sandvik Rock Processing.

“There is no doubt that the local market is ready for SAM, judging from the enthusiastic response we have had from customers,” says Jumaa. “Mines are looking to work smarter, and SAM provides this ability to operators, technicians, purchasing departments and managers alike.”

He notes that Sandvik Rock Processing has developed SAM in line with the concept of a proactive user journey, so it provides instant and valuable support for various steps in this customer-OEM relationship. SAM combines a wide range of tools, information and guidance in one place, acting as an always-on digital assistant for daily operations.

“For instance, maintenance and site managers can track their equipment’s performance in real-time from the convenience of a laptop, tablet or mobile phone,” he explains. “At the same time, the mine’s purchasing department can access the SAM web shop to find the correct part numbers, create shopping lists and submit orders.”

Service technicians use SAM to find up-to-date documentation and manuals on their equipment, while operators can find ways to increase operational uptime and availability. Extensive operating data from the crusher is collected by sensors and transmitted through a gateway into cloud storage, where it can be analysed in depth and utilised in a range of calculations, algorithms and models.

“The data and analysis allow customers to finetune their performance, while developing more effective predictive maintenance and ensuring no unplanned stoppages,” says Jumaa. “SAM provides customers with real-time insight into their operations supported by fact based recommended actions that inform the most appropriate operating and maintenance strategies.”

A key benefit of the SAM system is the visual way that it represents data to the user, he explains. Customers can quickly visualise exactly how long the crusher has been operational or has been idling, for instance. The platform’s interface is also intuitive and user-friendly, he adds, so that customers do not need extensive training to learn how to use it. The platform even has features to guide customers on how to use it.

Having demonstrated a step-change in wear resistance on mines globally, Sandvik Rock Processing’s HX900 wear protection plates are now being launched in Africa. 

The results achieved by the HX900 plates have been remarkable, extending wear life by many multiples in real life mining applications. The plates are mainly used in applications such as feeders, feed chutes, transfer chutes, skirt liners, rock box edge liners, load-haul equipment and buckets – in countries including Australia, Brazil, Peru, Sweden and the US. 

“What makes our HX900 wear protection plate so effective is the unique combination of two different mechanical properties in a single piece,” says Phumi Motsamai, Regional Manager Screening Media & Wear Protection Africa at Sandvik Rock Processing. “The nodular iron resists the high impact of material, while the cemented carbides provide outstanding resistance to abrasion.”

The performance of carbide, for instance, has been shown to last up to five times longer than white iron, and up to 20 times longer than quenched steel. The longer wear life means extended replacement intervals and lower total cost of ownership (TCO), says Motsamai. This brings a range of operational benefits including higher productivity through less downtime, and improved safety as maintenance technicians are less frequently in contact with equipment. There is also less need for high volumes of replacement inventory to be stored on site.

She explains that the nodular iron – also known as ductile iron – is a special type of cast iron with a characteristic microstructure that enhances its mechanical properties. It contains graphite in the form of nodules or spheroids, which impart ductility and toughness. 

“Nodular iron has a higher tensile strength and can undergo significant deformation without failing,” she says. “It absorbs energy well and has good fatigue resistance, making it ideal for components that are subject to dynamic and cyclic loading conditions.”

The cemented carbides in HX900 consist of hard carbide particles bonded together by a metallic binder of primarily tungsten carbide. With a hardness of about nine on the Mohs scale, tungsten carbide is one of the hardest known materials, just behind diamonds and cubic boron nitride. 

“This extreme hardness gives HX900 outstanding resistance to wear and abrasion,” she says. 

“Compared to quenched and tempered 500 HB steels, cast-in-carbides can last up to 10 times longer; this improvement can be up to 50 times longer compared to regular chromium carbide overlays and white iron.”

Motsamai cites a case study in which HX900 replaced Hardox 400 plates lining a transfer chute in a Brazilian gold mine. After the Hardox 400 plates had worn through after only two weeks and just 108,000 t of material throughput, the HX900 plates lasted 75 weeks – withstanding the passage of over 3,8 million tons of material. In a similar application, the HX900 replaced Hardox 500 wear plates – and extended wear life from 18 weeks to 52 weeks. 

“In a copper mine in Sweden, the wear life of Hardox 500 in an accelerator chute was just two weeks – or 600,000 t of production,” she says. “After they installed HX900 plates, the mine was able to achieve a wear life of 32 weeks or 9 million tons.”

This innovation also has important sustainability benefits for customers, she continues, as the carbide production makes a key contribution to the circular economy. 

“Our HX900 plates embody high levels of good sustainability practice, as they utilise 99% recycled nodular iron and 100% recycled cemented carbides,” she says. “Research has shown that using recycled materials in this way consumes 70% less energy and cuts overall carbon dioxide emissions by 40%.”