As African mining companies focus on improving plant availability while controlling operating costs, aftermarket optimisation is emerging as an increasingly important strategy for extending equipment life and improving comminution performance. Weir is helping mines achieve these objectives through the application of premium ESCO crusher liners and ENDURON screen panels, supported by local technical expertise and global engineering capability.
According to Natalie Makhanya, Weir’s Aftermarket Manager for Comminution in EMEA, the company’s aftermarket approach is centred on understanding each operation’s unique ore characteristics and wear patterns rather than simply supplying replacement components.
“Where customers are dealing with highly abrasive applications, we have been able to extend crusher liner changeout cycles to four to six weeks, while in less demanding environments liner life can extend to four to six months,” Makhanya says. “ENDURON screen media has delivered equally impressive results with wear life ranging from two to four weeks in high-impact feed zones and up to 24 weeks in dewatering applications.”
The longer service life translates into higher plant availability, lower maintenance costs, more predictable shutdown planning and improved safety by reducing maintenance interventions.
A recent optimisation project at an iron ore reprocessing operation in South Africa’s Thabazimbi region illustrates the value of this approach. After the site’s ore proved significantly more abrasive than anticipated, Weir worked closely with the customer and ESCO engineering teams in the United States over six months to analyse wear patterns, evaluate liner performance and optimise the design. The result was a 25% manganese ESCO liner that doubled wear life from two weeks to four weeks.
“The project demonstrates how combining local application knowledge with global engineering expertise enables us to develop solutions that deliver measurable improvements in performance,” JD Singleton, Comminution Director EMEA at Weir, says.
Similar results have been achieved elsewhere. A South African chrome producer increased crusher liner life from four months to six months after upgrading to ESCO liners, while a major iron ore operation in Liberia improved drainage efficiency and classification performance after introducing ENDURON screen panels on its dewatering screens.
The growing success of these aftermarket solutions complements increasing demand for ENDURON crushers and ENDURON Elite screens across Africa. Singleton notes that the latest ENDURON Elite screens incorporate high capacity exciter technology capable of generating up to 1,28 MN of force, allowing large screens to operate with only two exciters where competing designs often require three, reducing maintenance requirements by approximately 30%.
To support growing demand, Weir has significantly expanded its South African ENDURON screen media manufacturing operation from an initial 150 m² facility to a 3 500 m² production plant, with further expansion set to double production capacity and reduce lead times across the continent.
“Mines are increasingly looking for partners who can deliver technical expertise alongside reliable product supply,” Makhanya concludes. “Our focus is on working collaboratively with customers to optimise plant performance, reduce maintenance costs and create long-term operational value.”
