Tag Archives: Weba Chute Systems

Client Focus

OPTIMISE TRANSFER POINTS TO LOWER TOTAL COST OF OWNERSHIP 

The efficiency and reliability of transfer points are pivotal in lowering the total cost of ownership (TCO) on mines and minerals processing plants. These transfer points, where materials move from one conveyor belt to another, from conveyor to equipment or into storage facilities, are critical junctions that, when optimised, can lead to significant cost savings and operational benefits.

Mark Baller, CEO of Weba Chute Systems explains that transfer points serve as the heart of materials handling systems. “Chute systems ensure the seamless flow of bulk materials such as minerals and aggregates, from one process to another. However, these points are also prone to issues like spillage, dust generation, material degradation and equipment wear. Addressing these challenges is key to reducing maintenance costs, downtime, and overall TCO.”

Weba Chute Systems, a leader in transfer point solutions, has been instrumental in assisting mining and minerals handling operations to achieve lower costs and increased reliability. With decades of experience and a deep understanding of the unique challenges in bulk material handling, the company has developed innovative solutions that address the critical issues associated with transfer points.

Baller says that optimised transfer points are designed to minimise spillage and dust creation. “Using well-engineered chutes can greatly reduce material loss through the creation of excessive finds or spillages eliminating the need for frequent clean-ups. This not only lowers labour costs but also mitigates environmental and health risks,” he says. 

Properly designed transfer points ensure a smooth and controlled material flow, which is essential to prevent material degradation, and this is where Weba Chute Systems leverages its extensive experience and expertise. Using advanced flow control techniques, such as curved chute designs and flow aid devices, the company designs transfer points that help in maintaining material integrity and consistency.

Transfer points are often sites of high wear and tear due to the impact and abrasion of materials, and Weba Chute systems prioritises the use of high quality wear resistant materials of construction. The company’s robust structural designs further enhance the longevity of transfer points, providing a substantial reduction in overall maintenance costs. This focus on durability extends to the lifespan of equipment, reducing the need for frequent replacements and maintenance. 

“Safety and operational efficiency are at the core of Weba Chute Systems’ solutions, and by minimising the risk of blockages and equipment failures, we significantly enhance safety and ensure continuous, uninterrupted operations for our customers,” Baller says. “This not only boosts productivity but also minimises downtime, leading to significant cost savings.”

“Optimising transfer points in materials handling applications is a strategic move that can significantly lower the total cost of ownership, and this applies to both greenfield and brownfield installations,” Baller says. “Investing in well-engineered transfer points is not just about improving individual processes but rather a holistic approach to enhancing the entire materials handling system’s performance and profitability.”

Client Focus

GLOBAL SHIFT TO WEBA CHUTE SYSTEMS REPRESENTS GREATER EFFICIENCY

In bulk materials handling applications, the uncontrolled discharge from conventional chutes can lead to increased maintenance and replacement costs, as well as decreased productivity. Recognising these challenges, companies around the world, both large and small, have adopted Weba Chute Systems, a choice which represents a shift towards greater efficiency and less downtime.

Mark Baller, CEO of Weba Chute Systems, explains that there is a growing consensus across the globe that incorporating custom-engineered transfer chutes is paramount. “There are still some that overlook the significance of transfer points that are engineered for specific application requirements, ranking them below screens, crushers or feeders in the process hierarchy.”

Baller points out a critical misconception that undermines operational efficiency: the notion that initial savings from inexpensive inferior chutes outweigh long term costs. “This approach is flawed,” he argues, “as it inevitably leads to higher operational expenditure due to frequent maintenance, and in some cases unscheduled downtime.”

Highlighting the benefits of custom-designed solutions, Baller notes, “Proper initial design significantly lowers maintenance needs, improves material transfer, extends conveyor belt lifespan and boosts throughput. Moreover, our chutes are engineered to minimise environmental impact, reducing airborne dust and enhancing workplace health and safety.”

The Weba Chute Systems team, armed with extensive field experience and intellectual resources built up over decades of operation, approaches each project with bespoke solutions aimed at maximising return on investment. “Engaging with our clients during the design phase is crucial for tailoring solutions that not only meet but exceed expectations, and this includes both new transfer points as well as retrofits,” he continues.

Baller also sheds light on the pitfalls of retrofitting poorly designed chutes. “Correcting failures post-implementation is far from ideal. Opting for a sound design from the start eliminates such challenges, however we are often called upon to solve issues caused by poor decision making and this is where we are able to tailor make a chute system to deal with whatever challenge the customer is facing, ” he says. 

Leveraging Discrete Element Modelling (DEM) for validation, Weba Chute Systems prides itself on its engineering acumen. “DEM complements our vast engineering experience, ensuring that our transfer chutes excel in performance and durability,” Baller says.

Baller emphasises that Weba Chute Systems stands out from general fabricators, and says that the company’s proficiency goes beyond just designing transfer points. “Our team specialises in providing tailor-made solutions that improve materials handling, reduce maintenance needs and lead to considerable financial savings. The company’s dedication to high quality service is reflected in the positive feedback from customers and their achievements in operational efficiency,” he concludes. 

Client Focus

THE CRITICAL ROLE OF MAINTENANCE IN TIMES OF FINANCIAL CONSTRAINTS

In the face of declining commodity prices, the mining industry has increasingly prioritised cost saving measures, often leading to the suspension of capital expenditure (CAPEX). While such strategies may yield short-term financial relief, the importance of implementing comprehensive maintenance programmes has never been more critical. 

These programmes are essential for ensuring the reliability and performance of existing equipment, timely servicing, repairs and refurbishments, preventing failures that could severely impact operations downstream.

One of the more complex aspects of mining operations maintenance is measuring the wear life of transfer chutes, which involves tracking numerous components. The advantages of accurately gauging wear life are direct and substantial, contributing to enhanced operational uptime and, consequently, to the bottom line.

Mark Baller, CEO of Weba Chute Systems, sheds light on how the company’s customised reliability model plays a pivotal role in capturing key wear indicators for each chute. This model, when supplied with the correct data—including regular wear measurements—provides plant operators with invaluable insights into wear patterns. 

“Such insights are not just academic; they are practical, enabling predictions about which components will need replacement and the optimal timing for such replacements,” Baller explains. “This predictive capability facilitates meticulous planning, such as timely ordering of necessary parts to ensure they are on-site for upcoming maintenance windows. By adopting a proactive approach to maintenance, unforeseen stoppages are minimised, along with the accompanying disruptions and lost production time.” 

He emphasises the significant efficiency gains achieved through accurate predictions of component lifespan within their chutes. This efficiency is not confined to Weba Chute Systems’ maintenance contracts. The company extends the benefits of its reliability tool to all customers, offering the ability to request the service independently.

The application of reliability modelling allows for the generation of monthly reports, detailing the maintenance schedules required for each wear part within every chute. The model’s complexity accounts for differential wear levels across various parts of the chute, influenced by varying impact levels. This granularity enables chute owners to prioritise maintenance efforts on areas experiencing the highest wear, thereby optimising maintenance operations and ensuring continuous and reliable production.

Client Focus

WEBA CHUTE SYSTEMS: REVOLUTIONISING PERFORMANCE WITH SCIENTIFIC PRECISION

In the competitive and demanding world of mining, efficiency and sustainability are paramount. Mines are constantly seeking solutions that not only enhance operational effectiveness but also ensure environmental compliance and safety. Weba Chute Systems has emerged as a leader in this space, offering a scientifically-backed approach to measuring the performance improvements of their custom-engineered chute systems, ensuring customers can witness firsthand the reduction in total cost of ownership.

Weba Chute Systems stands out in the industry for its commitment to scientific accuracy and the tangible results it delivers. According to Izak Potgieter, Systems Manager at Weba Chute Systems, the company undertakes comprehensive product measurements to ascertain and validate the performance of its solutions. “Our team’s dedication to precision is unwavering,” Potgieter says. “We meticulously evaluate everything from dust levels to the wear and tear on essential components, ensuring we deliver comprehensive value.”

One of the key areas of focus is dust management—a critical concern in mining operations. Weba Chute Systems employs a detailed dust analysis programme that benchmarks its custom-engineered products against conventional chutes, offering end-users a clear picture of the improvements in terms of occupational health and safety standards. The meticulous measurement of dust particles, particularly those below 0.3 microns, underscores Weba’s ability to enhance workplace safety and environmental care.

The benefits of Weba Chute Systems extend beyond installation. The company has invested in extensive research and development to devise reliable calculation methods for maintenance planning. “Our model enables us to predict the lifespan of components with remarkable accuracy,” Potgieter notes. “This not only provides our customers with factual proof of our products’ durability but also empowers them with the knowledge they need to plan proactive maintenance, ensuring uninterrupted productivity.”

This scientific approach to both the performance measurement and maintenance planning of their chute systems sets Weba Chute Systems apart. It assures customers not only of a product that will enhance operational efficiency but also of a partnership aimed at maximising uptime and extending the life of their investment.

Potgieter says that the company’s dedication to scientific methods offers a clear message: investments by our customers in Weba chute solutions are validated by rigorous, unbiased analysis and backed by a commitment to excellence. 

“For mines looking to improve performance while adhering to the highest standards of health, safety, and environmental stewardship, we believe that Weba Chute Systems presents a compelling proposition. By reducing the total cost of ownership and guaranteeing the longevity and efficiency of transfer points, we are not just a supplier but a strategic partner in the mining industry’s quest for sustainable productivity,” Potgieter concludes. 

Client Focus

STRONG LOCAL, GLOBAL DEMAND FOR ENGINEERED WEBA CHUTES

It has been another good year for transfer chute specialist Weba Chute Systems, and signs are that it will get even better.

While demand from the mining industry can be volatile, the company has developed a solid pipeline of projects – not only in southern Africa but also abroad. Mark Baller, CEO of Weba Chute Systems, is expecting 2024 to get busier, and believes that this trend will continue into 2025. 

“As customers recognise the value of custom-engineered transfer points in their mines and plants, we have seen demand grow in various regions,” says Baller. “There are good prospects in countries like the Democratic Republic of Congo – where copper and cobalt mining is strengthening – and in platinum prospects in Zimbabwe, for instance.”

He notes that Weba Chute Systems has for many years been active in overseas markets, and is looking forward to fulfilling some large foreign projects. The company expects to supply a large package of about 50 chutes to a project in the US, and a gold mine expansion in Turkey will be supplied with up to eight custom engineered Weba chutes. 

“We continue to attract new customers who have heard about our specialised solutions, and who approach us with specific challenges they are trying to overcome,” he says. “We have had interesting engagements recently with companies operating in Jordan and Saudi Arabia – which promise to extend our reach beyond traditional markets.” 

Closer to home, Weba Chute Systems has continued to design and deliver substantial projects for Southern African customers. In South Africa, the company manufactured and installed 32 bespoke chutes for a steel plant. Through a leading EPCM company, it also supplied 10 large chutes to a platinum mine in Zimbabwe – to handle large run-of-mine material. 

“An expansion project at a local manganese producer has requested our services, so we have completed the engineering design for nine chutes and will soon begin the manufacturing process,” he says. “We have also been designing and delivering multiple chutes to three diamond mines in Botswana, and this will continue into next year.”

Baller highlights that the company has remained resilient to production disruptions such as loadshedding by the national utility in South Africa. As the owner of its design and manufacturing facility in Wadeville, south of Johannesburg, Weba Chute Systems has invested extensively in both renewable energy and backup power. This allows the facility to continue work uninterrupted, to meet customers’ deadline requirements without compromising quality. Its on-site solar power installation also assists in mitigating the rising cost of energy.

“By carefully managing our work environment and ensuring that all phases are fully resourced with the latest technology, Weba Chute Systems can deliver cost effective solutions that are tailored to each specific transfer point,” he explains. “For foreign contracts, we often have a cost advantage by conducting the design and manufacturing work in South Africa. At the same time, the value of our solutions is really measured by the extra production our customers achieve by optimising uptime through our high quality, engineered chutes.”

Client Focus

TRIBUTE TO WERNER BALLER – A VISIONARY AND PIONEER IN ENGINEERING (15/09/1940 – 15/12/2023)

Werner Baller, founder of Weba Chute Systems, passed away on 15 December 2023 leaving behind him a remarkable legacy. 

Werner, born in 1940 in Brotdhof, West Germany, embarked on a journey that not only changed his life but also revolutionised the bulk material handling industry across the world. With his National Diploma in Ceramic Engineering from Koblens / Rhein, Hoergrenshausen, Werner’s pursuit of excellence took him to South Africa in 1965, marking the beginning of a remarkable legacy.

The Rise of Weba Chute Systems

In 1983, Werner’s entrepreneurial spirit led him to acquire a small mining supply firm, M&J Engineering. His visionary approach transformed this company into Weba Chute Systems, a global leader in custom engineered chute systems for bulk material transfer. Werner’s innovative mindset resulted in the development of nine patented products, including the groundbreaking Weba Chute System, which revolutionised the industry with its unique ‘super tube’ or cascade design.

A Legacy Beyond Engineering

Werner was more than an entrepreneur and engineer; he was a beloved family man known for his passion, integrity and unconditional love. His legacy extends beyond his professional achievements, embodying the values of honesty and dedication in every aspect of his life.

Continuing the Legacy

Today, Weba Chute Systems, under the leadership of Werner’s son, Mark Baller, continues to be an industry leader, exemplifying the innovation and quality that Werner instilled. His induction into the International Mining Technology Hall of Fame in 2018 is a testament to his enduring impact on the industry.

A Tribute to a True Pioneer

Werner’s journey from a small German town to the pinnacle of engineering innovation is a story of determination, ingenuity and unwavering commitment. His contributions have left an indelible mark on the mining and engineering industries, and his legacy will continue to inspire future generations.

As we bid farewell to a remarkable man, we remember Werner Baller not only for his professional achievements but for the profound personal impact he had on those around him. His life’s work stands as a beacon of entrepreneurial spirit and engineering excellence.

Werner Baller (1940-2024), Founder of Weba Chute Systems, Innovator, Entrepreneur, Family Man.

Client Focus

WEBA CHUTE SYSTEMS HONOURED WITH SACEEC AWARD

Weba Chute Systems, a South African original equipment manufacturer specialising in custom-engineered chute systems, was honoured at the Exporter of the Year Awards hosted by the South African Capital Equipment Export Council (SACEEC) on 21 November 2023. This event recognised the significant contributions of industry players, highlighting 18 companies that exported over R8.4 billion to 67 countries last year.

The companies were evaluated based on several criteria, including marketing strategy, export turnover, local content, and participation in export promotion activities. The process involved strict confidentiality and expert judgment, including site visits to finalists’ premises.

Weba Chute Systems, celebrating its 40th year of operation in 2024, has established itself as a leader in transfer point design and manufacture, boasting over 5000 chutes successfully operating worldwide. The company’s focus on quality has been a cornerstone of its success, leading to its recognition as the Allied Services Exporter of the Year 2023 for companies with a turnover between R100 million and R150 million a year. 

Commenting on the significance of the award, Ted Cruickshank, Africa Business Development Manager, says that this accolade underlines Weba Chute Systems’ significant role in the industry and its contribution to South African exports. 

“The award acknowledges the continued demand worldwide for our custom engineered transfer point solutions. We have a solid pipeline of projects including platinum prospects in Zimbabwe and a busy copper landscape in the DRC, and just as importantly we are seeing exciting growth in a number of overseas markets,” he says. 

The company is looking forward to a major project in the US in 2024, where it expects to supply a large package of about 50 chutes. In Turkey, a gold mine expansion will take up to eight of its custom engineered chutes. Cruikshank says the company continues to be approached by new customers – recently in countries such as Saudi Arabia and Jordan – who have transfer chute challenges and have seen or heard about the company’s specialised solutions. 

Client Focus

NORTHERN CAPE MINE SMOOTHS FLOW WITH WEBA CHUTES

Specialist transfer point company, Weba Chute Systems is working with a mine in the Northern Cape to improve material flow. The mine has ordered two custom engineered chutes from Weba Chute Systems, which are expected to improve efficiency at the transfer points. 

According to Weba Chute Systems’ Regional Manager for the Northern Cape, Arnold Archer, the contracts are for an apron feeder discharge chute and a jaw crusher feed chute. Archer says the company had previously supplied the mine with a SAG mill feed chute, and had collaborated successfully to improve performance within that application. 

With run-of-mine material at the mine including large lump sizes of 800 mm to 1,2 m, there is a high risk of blockages if the chutes are not purpose-designed, he argues. The high velocity of the material can also cause considerable damage to chutes as well as create excessive dust. 

To inform Weba Chute Systems’ designs, the company’s team uses technical questionnaires to help gather information from the customer on a range of variables. This includes factors like lump size indicators, belt speeds, feed rates, moisture content and material velocity. The application-specific data paves the way for a design that optimises flow and equipment life.

“On the apron feeder discharge chute, for instance, we designed a swing door that will absorb most of the impact of big lumps moving at high velocities,” he says. “This also helps to protect the wear plates on the jaw crusher.”

The aim of the design will be to assist the mine reduce the incidences of chute blockages, spillage and excess dust – making the process more streamlined and less labour intensive. He points out that the mine aims to achieve higher uptime through optimal chute performance. The reduction in spillage and dust also contributes to the mine’s high standards of health and safety. 

“Our philosophy is that every transfer point on a mine has its own specific challenges, so the chute for each transfer point will be different to the next one,” he says. “We work with customers to understand the detail of their material flow through these points, so that our design takes all the key factors into account.”

He notes that most mines will have the necessary data gathering systems in place to inform the correct chute design – as they have tachometers on their conveyors, blocked chute detectors and feed monitors. The issue is just that this information is not always systematically considered during chute design. 

“We are proud of the chutes we design and manufacture, and stay close to our customers to ensure that the chutes’ performance is up to expectation,” Archer explains. “Our staff is passionate about getting everything right, and being there to follow up where necessary.”

Among the improvements made on the SAG mill feed chute at the mine, for example, were changes to the liner composition and pattern. Rather than removing all the liner segments to reach the middle row, the pattern change now allows this row to be removed without loosening all the other liners, he says. 

Weba Chute Systems can also install its own chutes, but provides supervision and assistance where the mine arranges the installation itself, he concludes. 

Client Focus

OPTIMISING TRANSFER POINTS IN BROWNFIELDS PROJECTS

As mining companies embark on brownfields initiatives to meet rising market demand for battery and other minerals, the optimising of transfer points presents a valuable opportunity to deliver more output cost effectively.

Alwin Nienaber, Technical Director at Weba Chute Systems, says that when correctly used technology and experience provide a powerful combination when expanding production capacity. Technology can be leveraged to facilitate rapid and accurate scanning of the existing configuration of infrastructure into which the improved chutes are to be installed. Further, he says, the company brings a wealth of expertise to advise on valuable adjustments in the relationship between chutes and other equipment.

Alwin Nienaber, Technical Director at Weba Chute Systems.
Alwin Nienaber, Technical Director at Weba Chute Systems.

“Custom engineered chutes and transfer points have been shown to facilitate smoother flow of mined material, with greater reliability and uptime for a more streamlined and productive operation,” explains Nienaber. “The initial focus when providing transfer point solutions to a brownfields project is usually to take careful note of the physical layout so that chutes are designed with spatial constraints in mind.”

This can be most accurately and efficiently achieved using 3D laser scanning of the existing layout, to rapidly gather detailed measurements of large infrastructure on a customer’s site. Using this data, a precise 3D model can be generated on the basis of which the necessary chutes and componentry can be designed and manufactured.

“This aligns well with Weba Chute Systems’ considerable in-house expertise in chute design, as each chute we build is unique to the application it serves,” Nienaber says. “It is important to remember that every transfer point exists in a relationship to other equipment, such as a screen, crusher or conveyor belt.”

Weba Chute Systems Technical Manager, Dewald Tintinger, using the 3D laser scanner to take dimensions on site.
Weba Chute Systems Technical Manager, Dewald Tintinger, using the 3D laser scanner to take dimensions on site.
Central belt loading being discharged from a Weba chute at a steel plant in Turkey.
Central belt loading being discharged from a Weba chute at a steel plant in Turkey.
Weba chutes installed at a steel plant in Turkey.
Weba chutes installed at a steel plant in Turkey.
Weba chutes, with samplers, installed at a steel plant in Turkey.
Weba chutes, with samplers, installed at a steel plant in Turkey.

He highlights that an understanding of this relationship will underpin the productive application of transfer point design and installation. Indeed, while the 3D scanning and modelling technology provides a valuable starting point for design there is also scope for added improvements in the plant layout.

“On so many of the sites that we visit and assess, we can soon identify where changes in the relationship between the transfer points and other equipment can deliver better results,” says Nienaber. “While it is sometimes difficult – even costly – to implement some of these changes, the customer reaps many times the value in terms of uninterrupted volume flow, uptime and productivity.”

The first prize when installing transfer points, he emphasises, is always the optimal solution – which may mean reconsidering the position of the upstream and downstream equipment. In fact, this is always the starting point for Weba Chute Systems’ transfer point solutions: to achieve the most productive result for the customer.

“With our engineered design approach, we always consider the context of where our chutes are going to operate, and our decades of field experience allow us to advise the customer what will work best,” he says. “We might advise on how adjusting the position of a conveyor’s head pulley, for instance, would improve chute performance and overall plant efficiency.”

He notes that, while certain configuration changes might exceed budget constraints, the company’s intervention often allows for positive modifications to be made. A recent example of this was in a contract for a South African iron ore producer in the Northern Cape. Weba Chute Systems was asked to address the mine’s challenge where an existing competitor’s chute needed attention every two days  which was severely hampering production.

“We designed and installed the optimal customised chute, but also recommended some related adjustments,” he says. “The design was a split chute, and the plant needed to speed up its conveyor quite considerably – as well as lifting the head pulley slightly – to achieve the necessary results.”

The changes recommended had financial implications, so the customer required considerable certainty that the solution would be successful. To underpin its plan, Weba Chute Systems digitally modelled the proposed design and simulated its operation using software that visualised the movement of material through the chute.

“Used by our skilled designers, this powerful software delivers more than a pretty picture,” emphasises Nienaber. “The simulation presents in video format exactly how equipment will be positioned and how material will flow through the system.”

Fundamental to these kinds of solutions, of course, is a close collaboration with the customer, built on a high level of trust in the company’s past performance. Aligned to this is Weba Chute Systems’ commitment to see through any project it embarks upon, he says.

“Our customers know we never walk away from a project – and this is an important factor in brownfields projects where one is often working within existing constraints rather than a clean slate,” he argues. “We have confidence in our people and our designs, and remain accountable for any solution we provide until it performs to levels we have promised.”

Another important factor in many projects is the level of degradation of mined material, which the company prides itself on reducing through its scientific, streamlined approach to the dynamics of bulk materials handling.

“An example of where this was important was a steel plant in Turkey where we installed a number of our chutes,” he explains. “The customer required minimal ore degradation, and even monitors the ore passing through each chute to ensure fines generation is kept to a minimum.”

Weba Chute Systems was required to incorporate samplers in its installations in this plant, and these samplers generate the data to verify the chutes are performing to expectation. The company’s custom design allows greater control over the direction, flow and velocity of material, whose volume and characteristics are specific to each application.

Client Focus

ZIMPLATS SEES SIGNIFICANT DUST REDUCTION AND INCREASED PRODUCTIVITY WITH WEBA CHUTE SYSTEMS

Custom engineered chute systems have significantly reduced dust levels while increasing productivity at Zimplats. Over the last two decades, Weba Chute Systems has installed 99 of its tailormade transfer points in various applications across the mine and processing plants.

Showing a rendered image of the transfer chute at the conveyor underground decline conveyor.
Showing a rendered image of the transfer chute at the conveyor underground decline conveyor.
Showing a rendered image of the crushing discharge transfer chute.
Showing a rendered image of the crushing discharge transfer chute.
Showing a rendered image of the crushing station vibrating primary jaw crusher transfer chute.
Showing a rendered image of the crushing station vibrating primary jaw crusher transfer chute.
Showing a rendered image of the crushing station vibrating grizzly transfer chute.
Showing a rendered image of the crushing station vibrating grizzly transfer chute.

These bespoke installations span various applications including conveyor onto conveyor transfer chutes, apron feeder discharge chutes, mill feed chutes, conveyor onto bins transfer chutes, screen over and under size chutes, silo chutes, and transfer chutes at the crushing and screening stations.

Weba Chute Systems recently secured another contract to provide ten custom-engineered transfer chutes for the expansion of an underground crusher station at Zimplats.

Izak Potgieter, Systems Manager at Weba Chute Systems.
Izak Potgieter, Systems Manager at Weba Chute Systems.
Ted Cruickshank, Project Manager at Weba Chute Systems.
Ted Cruickshank, Project Manager at Weba Chute Systems.

Ted Cruikshank, Weba Chute Systems’ Project Manager, explains that these chutes will handle the transportation of run-of-mine material from the ore pass to the underground crusher and from the crusher to the outgoing conveyor. He says the engineering and construction of these chutes will ensure a fit-for-purpose robust solution with the height of the chutes ranging from two to six metres.

Sharing specifics, Cruikshank say that the chutes before the crusher are designed to manage large material up to 650 mm in size from a vibrating feeder, with a maximum tonnage of 1,100 tph. “Other chutes will transport the feeder’s undersize, less than 180mm in size, at 550 tph, while still others will be employed in conveyor-to-conveyor applications, feeding 1,500mm wide belts with up to 1,350 tph of material and a maximum lump size of 250mm.”

Weba Chute Systems’ unique chute design philosophy, based on the cascade system, extends the wear life of the chute through the strategic placement of dead boxes, creating a layer of ore for the moving material to flow over. Replaceable lips are incorporated on the dead boxes facilitating easy and quick swap out at the necessary intervals. Easily accessible inspection doors are also a feature which will ensure maintenance becomes an effortless process.

Cruikshank says that this design has proven particularly effective at Zimplats due to the abrasiveness of platinum ore, and the Weba chutes will continue to ensure the smooth, controlled flow of mined and crushed material, leading to less wear, damage and spillage on conveyor belts and a marked reduction in dust.

Weba Chute Systems’ innovative design has been particularly effective in reducing dust levels. Izak Potgieter, Systems Manager at Weba Chute Systems ,cites the example of the bunker discharge chutes.

“In this application considerable dust levels were created due to material of up to 500 mm in size moving through the conventional transfer point at a rate of 600 tph with no control of the material result in an uneven flow creating a lot of energy for dust particle to expand into the surrounding atmosphere.”

Following the replacement of the conventional transfer point with a custom engineered Weba chute dust levels were considerably reduced by about 40% and Potgieter explains that by controlling the velocity of the material it is not only possible to reduce dust generation but also to improve flow control reducing impact and wear which in turn minimises maintenance downtime.

Hilmax, Weba Chute Systems’ local agent in Zimbabwe, will oversee the chute installations and provide spare sets of wearing lip liners for each chute to ensure optimal uptime for Zimplats.