With most of its 5,000-strong global footprint of transfer chutes being installed in Southern Africa, Johannesburg-based Weba Chute Systems has built a reputation in demanding mining conditions.

The region is a leading producer of platinum and manganese, for instance, which are both highly abrasive ores, points out Dewald Tintinger, Technical Manager at Weba Chute Systems. The company’s innovative approach and customised designs control material flow and resist wear, matching specific site conditions.

“First and foremost, a chute must facilitate optimal throughput so that mining production is not hampered by frequent blockages or repairs,” says Tintinger. “It is well known that the cost of a quality chute is a fraction of the cost of lost production through downtime.”

He highlights that Weba Chute Systems takes a systematic approach to assessing each customer’s requirements, starting with the general arrangement of the area around transfer points. The depth of experience accumulated over 40 years in business allows the company’s experts to suggest improvements to the layout – where these are possible and where they affect the chute performance.

“Then we consider a range of key factors like the material characteristics, the throughput tonnages and speed of travel, when we plan the design,” he says. “These considerations guide the application of our controlled flow philosophy.”

The design is built on scientific calculations using the anticipated trajectories, impacts and pressures on the structure. The main conceptual options are Weba’s Cascade Chute with dead boxes, the Weba Superflow chute with liners or a combination of both. 

“A key element of our popular Cascade Chute is the use of dead boxes and lips on the inside of the structure, which traps material and allows other material to flow over it,” says Tintinger. “This ensures that up to 70% of the wear surface is protected by stationery material, which substantially reduces wear and maintenance costs while extending service intervals.”

As material enters the chute and flows through, it lands mainly on other material which absorbs the impact more effectively, protecting the underlying wear plates and structure from undue damage. This also reduces dust creation, he notes, which is an ongoing health and safety concern on mines.  

“Controlling material flow through the right chute design also protects costly equipment like conveyor belts,” he says. In one example, Weba Chute Systems installed a cascade chute at a Southern African copper mine to better control the flow of material onto conveyor belts. This saved immediately on belt costs – while boosting productivity through improved uptime.

Controlling dust during material transfer has become a pressing challenge in mining and industrial operations, particularly as environmental regulations tighten and safety standards rise. Dust emissions can pose significant health risks to workers, affect local communities and damage nearby ecosystems. In response to these concerns, Weba Chute Systems has emerged as a leader in the design and manufacture of advanced transfer chutes, with solutions specifically engineered to minimise dust generation while improving overall operational efficiency.

Mark Baller, Managing Director of Weba Chute Systems, explains how traditional chutes were once seen as basic components, designed simply to move material from one point to another. “Early chutes were often little more than boxes,” he says, “with minimal attention paid to the broader implications of their design, such as dust control or material degradation.” Over time, however, as industries have prioritised safety, efficiency and environmental responsibility, the role of transfer chutes has transformed. Now, they are considered essential tools for controlling dust and optimising material flow.

Weba Chute Systems has been at the forefront of this evolution. Its chute designs incorporate sophisticated features such as the “supertube” principle, which regulates the flow of material and reduces the turbulence that typically leads to dust generation. By creating a smoother, more consistent stream of material, Weba chutes can significantly limit the escape of fine particles at transfer points. This, in turn, reduces the amount of dust that can be carried by the wind, helping to protect nearby communities and ecosystems from pollution.

The benefits of these designs are evident in the field, with some operations experiencing up to a 77% reduction in dust levels after installing Weba chutes. This reduction has not only improved environmental conditions but has also allowed for safer working environments, as lower dust levels enable more regular inspections and maintenance without the need for costly shutdowns.

In addition to controlling dust, Weba chutes are designed to address material degradation and segregation—critical issues in industries where fines content must meet specific requirements, such as in iron ore and manganese mining. Fines are more prone to becoming airborne and generating dust, but by ensuring a consistent material stream, Weba chutes minimise segregation and maintain material quality.

Effective chute design also optimises material distribution in storage silos. Weba’s rotary chute, for instance, helps blend fines and coarser material more evenly, ensuring consistent material performance at various points within the silo. This not only improves efficiency but also reduces operational disruptions.

Through a combination of engineering excellence and a focus on safety and environmental sustainability, Weba Chute Systems continues to set the standard for dust control and operational efficiency. As industries face increasing pressure to operate responsibly, Weba’s advanced chute technologies provide critical solutions that help balance productivity with environmental stewardship.

In the bulk material handling applications transfer points are critical locations where materials are moved between different conveyor belts or from conveyors to storage areas. The efficiency of these transfer points plays a pivotal role in maintaining a steady flow of materials, reducing downtime and minimising operational costs. As these applications evolve, several significant trends are shaping the design and functionality of transfer points, reflecting a focus on reducing spillage, optimising material flow and enhancing safety.

Weba Chute Systems has been at the forefront of addressing these evolving trends with its innovative approach to transfer point technology. The company’s chutes are custom-engineered to ensure smooth material flow, reducing impact angles and directing materials in a controlled manner. 

Mark Baller, CEO of Weba Chute Systems, explains that this design philosophy pioneered by his father, the late Werner Baller, minimises wear and tear on both the chutes and downstream conveyor systems, significantly lowering downtime and maintenance costs. 

Reducing material spillage is a challenge that has driven innovation in transfer point technology. Spillage not only results in material loss but also increases maintenance and poses safety risks. 

“We also incorporated advanced dust and spillage control features into our designs, and specifically the controlled flow achieved by Weba chutes reduces turbulence and material scatter help to contain dust and minimise environmental and health risks,” he says. 

Safety is another critical area where Weba Chute Systems excels, with chute designs that provide easy access for maintenance and robust safety barriers to protect workers. The integration of new technologies, such as sensors and remote monitoring systems, enables real-time data collection on chute performance, allowing operators to anticipate maintenance needs and avoid unexpected downtime.

Baller explains that the use of advanced computational fluid dynamics (CFD) modelling, something which the company has been doing for many years, allows the company’s engineers to simulate and analyse material flow at transfer points with great precision. 

“By understanding how materials behave as they pass through these junctures, our engineers can identify potential problem areas, such as blockages or high wear zones, and adjust the design to ensure a smoother, more controlled flow. This approach helps to reduce impact and abrasion, extending the lifespan of the equipment and minimising maintenance requirements,” Baller continues. 

Material choice is also a critical factor, with a growing emphasis on wear resistant materials that can withstand the harsh conditions typical of bulk material handling environments. High quality abrasion resistant steel, ceramic liners and composite materials are increasingly being used to line chutes and other components exposed to high impact or abrasive materials. These materials not only enhance the durability of the equipment but also reduce downtime due to less frequent repairs or replacements.

As the demand for more efficient, durable and safe transfer point solutions continues to grow, companies like Weba Chute Systems are well-positioned to meet these evolving requirements. By continuing to set new standards for performance and longevity, Weba Chute Systems are ensuring that material handling operations run smoothly and efficiently, maximising productivity and reducing costs for bulk materials handling operations. 

In the mining environment, chutes are generally designed to manage some variance in the loads being transported by conveyor systems – but drastic changes in conveyor belt speeds can introduce complications.

According to Dewald Tintinger, Technical Manager at Chute Systems, chutes are designed with the width of the conveyor belt in mind – accommodating the various levels of loading on these belts. Changing the speed of the belt significantly, however, can affect not only the volume of material entering the chute, but the first point of contact in the chute as the material leaves the belt.

“The speed of the conveyor belt has a direct impact on the trajectory of material when it reaches the chute,” says Tintinger. “When changing the belt speed from 2,5 m/s to 3 m/s, for example, the chute would easily accommodate this. However, if the speed was doubled, this would change the trajectory so that the material impacts a different point in the conveyor, and at a different angle.”

He explains that Weba Chute Systems adopts a customised approach to each chute’s specific application, modelling the flow of material to guide the final design. Among the calculations is the initial velocity of the material leaving the conveyor belt, and the precise impact point on the inside wall of the chute.

Using the dead box principle to optimise material-on-material flow, the position of the first dead box in the chute will match this impact point. A higher speed of material will start to straighten the trajectory and change the impact angle.

“As the impact angle approaches 90 degrees, there is a risk that material flow could stall,” he says. “Rather than slowing down on impact and then accelerating downward towards the discharge point, the material could start backing up and clog the chute.”

While some chute manufacturers introduce platework to bend the trajectory of material, this adds to the wear on the chute. Weba Chute Systems generally applies its full cascade designs, using dead box sections to reduce the impact and speed.

“The change of angle of material onto the first dead-box will not necessarily change the flow pattern, but it is likely to affect the speed of material through the chute,” says Tintinger. “It is therefore important to check the chute’s capacity to still allow enough material to pass through smoothly.”

General maintenance service providers often overlook the intricate engineering design of specialised on-mine equipment, leading to significant long term costs for mining operations. This issue extends to transfer chutes and other mining infrastructure, Farouk Abrahams, Sales Director at Weba Chute Systems, notes. He explains that poor maintenance typically results in unscheduled stoppages due to equipment failure,  compromising mining operations.

Abrahams points out that mines often outsource maintenance to general service providers in an effort to cut costs. Ironically, this approach often results in the opposite effect, with production revenue suffering due to these misguided cost-saving measures. He emphasises that inadequate maintenance undermines the value that original equipment manufacturers (OEMs) promise.

“For Weba Chute Systems, our chutes are custom-engineered for specific duties; any shortcuts in maintenance, such as using inferior materials, can significantly reduce performance and lifespan. This can lead to costly operational consequences including increased impact on conveyor belts, resulting in damage, spillage at transfer points and higher dust emissions—all requiring immediate attention,” he says.

The value brought by OEMs extends beyond just the physical products they supply. OEMs bring a wealth of specialised experience to each product, adding considerable value to a mine’s overall efficiency, safety and profitability. Their deep understanding of the equipment’s design and operational demands ensures maintenance performed will uphold the equipment’s performance standards.

“This expertise translates into smoother mining operations, as our team’s extensive practice in the field allows them to guarantee the outcome of every intervention. The reliability offered by OEMs such as Weba Chute Systems, extends to the timely sourcing or delivery of spares and the convenient scheduling of necessary maintenance.”

Abrahams shares that poor maintenance can drastically reduce plant availability. For instance, by collaborating with a customer on maintenance, Weba Chute Systems was able to maintain plant availability as high as 98%. However, when the mine switched to a general contractor to save costs, availability plummeted to below 90%. Such a decline in performance can be catastrophic for a mine, with minimal operating expenditure savings far outweighed by revenue losses.

Moreover, the impact of inadequate maintenance on specialised equipment like transfer chutes can extend beyond immediate operational issues. The cascading effects of reduced equipment efficiency can strain other parts of the mining operation. “For example,” Abrahams says, “compromised chutes can lead to irregular material flow affecting downstream processes and equipment, increasing wear and tear and necessitating more frequent repairs and replacements. This not only disrupts production schedules but also inflates maintenance budgets.”

“When we maintain our own equipment, we uphold the high standards to which the equipment is designed and manufactured. This commitment ensures reliability and has earned our customers’ trust, demonstrating the true value of specialised maintenance over general service providers,” he says. By ensuring that every component and material used meets the stringent requirements of the original design, OEM maintenance preserves the integrity and efficiency of the equipment, safeguarding the mine’s operational continuity and profitability.

In addition, partnering with OEMs for maintenance can provide mines with access to the latest technological advancements and updates. OEMs are continually improving their designs and incorporating new technologies to enhance performance and efficiency. By engaging with the OEM for maintenance, mines can benefit from these innovations, ensuring their equipment will perform reliably.

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.”

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. 

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.

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. 

With the promise that its customised transfer point solutions will always perform to expectations, Weba Chute Systems tackles its turnkey projects in a highly systematic and controlled manner.

The company has successfully carried out more than 25 turnkey projects in the past decade, according to Weba Chute Systems project manager Ted Cruickshank, including contracts in the mining, steel, ports and food industries. Among these substantial projects was the design, manufacture and installation of 36 chutes at a steel maker’s sinter plant in South Africa, and 11 chutes for a project house developing a mine in Zambia.

“More recently, we completed a turnkey project for a number of crusher chutes at a platinum mine in Zimbabwe,” Cruickshank says. Further afield, Weba Chute Systems has provided chute designs to accommodate a three-way conveyor in an operation in Trinidad and Tobago in the Caribbean, now awaiting execution.

Attention to detail

“It all starts with defining the project’s objectives and scope,” explains Cruickshank. “This is followed by establishing the budget so that an accurate quotation can be prepared, as well as planning a timeline that meets the customer’s schedule.”

Turnkey projects demand clear channels of communication, he emphasises, so a regular meeting schedule is agreed with the customer to ensure that all stakeholders are kept informed throughout the project cycle. This is particularly important for dealing timeously with issues so that the project’s progress is not unduly impeded.

“On some projects, we can work off the customer’s drawings, but we often go to site to conduct our own surveys, on which we base our calculations and designs,” explains Cruickshank. Chute flow designs and layouts are then completed and approved, followed by fabrication approvals – all within a stringent Quality Control Plan (QCP).

Eyes on quality

“Our efficient procurement allows fabrication to get underway without delay, and stringent quality checks are carried out at every stage of manufacture,” he says.

Cruickshank emphasises that rework needs to be avoided if projects are to run on-time and on-budget, and this means stringent quality control. Weba Chute Systems uses ISO 9001-2015 as the standard to document and control all quality related activities.

“Regular audits and certifications help maintain a high level of consistency in the quality of our products across all projects,” he says. “Quality inspections at different project locations ensures that the equipment adheres to the project’s quality standards.”

Mitigating risk

A risk assessment on each project identifies all potential hazards and is the basis for mitigation plans to reduce risk. There is also growing pressure on mines and their contractors to minimise environmental impacts.

“Noise, dust and spillage are among the main environmental risks associated with transfer chutes,” he notes. “We mitigate these impacts through optimising the flow dynamics in our tailored chute designs – accommodating the specific conditions of each application.”

This includes understanding the material’s characteristics and particle size distribution, as well as its flow rate, trajectory, velocity and points of impact. Optimised material flow decreases the turbulence at the transfer point, in turn reducing dust and noise. Smooth transfer of material to and from conveyor belts also cuts the spillage and improves health and safety conditions around the belts.

Leveraging technology

He highlights the value of project planning software to plan and monitor progress during turnkey projects. These tools enhance real-time collaboration and efficiency, with other enabling technologies including three-dimensional modelling and data management.

“We also use video conferencing and cloud-based document handling to streamline our communication with customers and other parties to the project,” he says. “This improves overall efficiency and resource coordination.”

Cruickshank concludes by highlighting the value of local suppliers, engineers and partners in the country where the turnkey project is being executed. Weba Chute Systems prioritises these links by building positive long term relationships with local partners to overcome potential barriers of culture, language, lead times and cost efficiency.