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We are a global management consultancy that delivers exceptional outcomes and sustainable change

Case Study

Pro­cess­ing Plant – Improve­ment Hard Rock Tons per Hour / Tons per Day


Our client, one of the world’s lead­ing mid-tier gold min­ing company.

Key Results 


Poten­tial Improve­ment Hard Rock Tons per Hour at Gyra­to­ry Crusher 

Opti­miz­ing our Process Plant begins with man­ag­ing the sizes of the ore at the dif­fer­ent stages of the process. This begins with the larg­er size ore being deliv­ered by Haul Trucks from the mine to the very fine par­ti­cle size required to recov­er the gold from the ore.

At the ini­tial stage, the open­ing of the Gyra­to­ry Crush­er was reduced from 6.0 inch­es to 4.5 inch­es. The open­ing at the Sec­ondary Crush­er was reduced to 1.5 inch­es. The Apron Feed­er, anoth­er com­po­nent ear­ly in the process, has been rebuilt increas­ing a test­ed capac­i­ty from 1,200 to 1,700 tons per hour. The repair on the tun­nel also now enables the speed increase of the Apron Feed­er from 65% to 75%.

In addi­tion to the increased process capac­i­ty, less ener­gy is required which reduces our costs and helps the envi­ron­ment.
Also, a refur­bished rock break­er is cur­rent­ly being installed to reduce down­time and increase throughput.


  1. Man­ag­ing the “F80” / size of ore feed­ing into the Plant
  2. Man­ag­ing the CV2 con­vey­or (Hard Rock) and CV3 con­vey­or (Soft Rock)
  3. Replaced the Head Pul­ley for less slip­page and less lagging
  4. Poten­tial now to process dai­ly demand of ore in 12 hours using two 777s and one 993LU for improved blending
  5. Refur­bished rock break­er now being installed

* We take client con­fi­den­tial­i­ty seri­ous­ly. While we have kept the brand anony­mous, the results are real.

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