Sandvik Rock Processing has established a dedicated exciter repair and refurbishment capability at Sandvik’s Kitwe facility, giving Zambian mining customers faster access to OEM-standard service without cross-border transport. The investment cuts turnaround times and logistics costs while strengthening local technical capability, lifecycle support and equipment uptime.
Initially focused on Sandvik Rock Processing’s installed base in Zambia, the new capability will reduce turnaround times and transport costs while removing the logistical burden associated with moving high value components across borders.
Ivan Senekal, Sales Development Manager for Africa at Sandvik Rock Processing, says the Kitwe operation now matches the capability of the company’s established exciter service facility in Johannesburg.
“The shorter turnaround time also allows customers to reduce their inventory of spare exciters, freeing up working capital that would otherwise be tied up in these high-value components,” Senekal says.
The local facility also provides greater flexibility in the event of an unplanned failure. Where an emergency occurs or maintenance planning falls short, having an in-country repair capability gives customers greater control over the process.
“With cross-border transport, there are always factors outside the customer’s control that can influence turnaround time,” he notes.
Exciters can now be transported from mines to Sandvik’s Kitwe facility within a matter of hours, says Makumbi Mulenga, Service Manager Central Africa at Sandvik Rock Processing.
Importantly, the new exciter workshop also represents a deliberate capacity-building initiative for Zambia, supporting increased local content within the country’s mining services sector.
“Our Zambian team was specifically trained in exciter refurbishment in South Africa and continues to receive practical support in Kitwe from experienced Sandvik Rock Processing specialists,” Mulenga explains. “Together with the specialised equipment installed at the facility, this ensures that all equipment is refurbished to OEM standards.”
He emphasises that the refurbishment process is aligned with Sandvik Rock Processing’s Johannesburg operation and follows the same procedures and quality standards.
“Our new exciter repair capability is subject to Sandvik Rock Processing’s compliance oversight,” he says. “This means customers choosing local refurbishment receive the same end-product standard without the need for cross-border transport.”
Senekal highlights the highly technical nature of the service, noting that exciter refurbishment requires more specialised expertise than conventional gearbox repair.
“The exciters used on vibrating screens are subjected to substantial dynamic forces and operate continuously at high rotational speeds,” he says. “Within our installed base in Zambia, for example, the units rotate at around 800 rpm and generate forces in excess of one meganewton each.”
During refurbishment, exciter components are measured to micron-level precision to determine which parts require replacement. Reassembly then follows a prescribed procedure and sequence, using dedicated equipment to ensure consistent and repeatable results.
Before being returned to customers, refurbished exciters undergo full-load testing at the Kitwe facility. According to Senekal, each unit is operated at 100% load for several hours on a dedicated test bench, replicating the conditions it will experience in service.
Namit Sachar, Business Line Manager for Parts & Service at Sandvik Mining Central Africa, says the investment supports the company’s broader lifecycle support strategy, with an increasing focus on equipment uptime and predictability.
“Customers are concerned with more than just the repair cost,” Sachar says. “They also need confidence in how long critical equipment will be unavailable and how predictable the repair process will be.”
He says the investment further demonstrates Sandvik’s long-term commitment to Zambia, strengthening its existing infrastructure through the addition of specialised workshop and testing equipment as well as ongoing knowledge transfer and rigorous quality procedures.
“With the new exciter facility, customers get more than a repair,” Sachar says. “They get greater certainty that critical equipment will be returned to operation quickly and will perform as-new.”
