As the mining sector increasingly relies on Engineering, Procurement and Construction Management (EPCM) firms for new builds, expansions and plant optimisation, the strategic integration of transfer points in the early stages of project planning is gaining recognition. Mark Baller, CEO of Weba Chute Systems, emphasises that engaging transfer point specialists at the feasibility stage can significantly enhance plant performance and cost efficiency.

"EPCMs play a crucial role in ensuring projects are executed efficiently, but to truly maximise value they need to involve transfer point specialists at the earliest phases," says Baller. "Too often, transfer points are considered late in the process, leading to costly design alterations and operational inefficiencies."

He notes that in the past, transfer chutes were often regarded as minor components in plant layouts with more focus placed on high-capital items. However, the industry is now recognising the substantial impact that poorly designed chutes can have on plant performance.

"When transfer points are not optimally positioned or engineered, mines experience a range of issues from material choking and excessive wear to belt misalignment and spillage," Baller explains. "These problems translate directly into increased downtime, higher maintenance costs and disruptions to the entire process."

By integrating transfer point expertise early on, EPCMs can avoid these challenges while improving cost predictability for their clients. Baller highlights that key factors such as chute height, ore flow dynamics and impact control must be considered before finalising plant layouts.

"Once critical equipment positions and heights are set without our input, achieving optimal material flow can become a challenge," he says. "Retrofitting solutions or making late-stage design adjustments inevitably increases costs, something no mine operator wants. Getting the design right from the start ensures efficiency and enhances the reputation of the EPCM."

A case in point, Baller notes, is a manganese mine in South Africa’s Northern Cape that approached Weba Chute Systems after experiencing severe material flow disruptions due to inadequate chutes. The mine was plagued by high wear, frequent breakdowns and operational inefficiencies.

"We stepped in to redesign and replace nearly 30 chutes at the site," he recalls. "The results were immediate - improved material flow, reduced maintenance requirements and a return to normal operations."

One of the key advantages of Weba Chute Systems’ technology is its scientific approach to material transfer, ensuring that ore moves through the system with controlled velocity and minimal impact. This prevents excessive wear on conveyor belts, extends the lifespan of plant equipment and reduces dust generation, which is a growing concern in many mining operations. Additionally, Weba’s custom-engineered chutes are designed to handle a variety of materials ensuring optimal performance across different mining applications.

Beyond efficiency, Baller also underscores the safety benefits of Weba Chute Systems’ maintenance-friendly designs. "Our chutes are engineered for easier access and quicker maintenance, reducing downtime while ensuring a safer working environment for maintenance teams."

With EPCMs continuing to shape the future of mining infrastructure, Baller urges them to rethink their approach to transfer points. "Considering transfer chutes early is not just a design choice - it’s a strategic move that optimises plant performance, minimises costs and enhances overall project success. By leveraging our proven expertise, EPCMs can ensure long-term operational reliability for their mining clients."