In the high-pressure environment of bulk materials handling, transfer chutes play a more pivotal role than many realise. While often overlooked, these components are critical to ensuring seamless flow, minimising downtime and reducing maintenance costs. And as Mark Baller, Managing Director of Weba Chute Systems, points out, the difference between a standard chute and a custom-engineered solution can have far-reaching operational and financial consequences.

With more than 5,000 chutes installed across mining, power generation, ports and industrial plants around the world, Weba Chute Systems brings over four decades of experience and technical insight to each project. The company’s core belief is simple: chutes must be engineered for the specific application and site conditions. “Too many operations fall into the trap of using generic transfer point solutions,” says Baller. “But the reality is that every plant handles different materials with different flow behaviours and impact forces. This requires a scientific and tailored approach.”

Weba Chute Systems differentiates itself through its controlled flow designs which reduce velocity and manage impact, resulting in less turbulence, spillage and dust. The design process is underpinned by Discrete Element Modelling (DEM) software which simulates material behaviour through the chute. This enables engineers to visualise how material will move under real-world conditions - predicting wear patterns, identifying potential blockages and optimising liner placement before the chute is built.

The result is a transfer system that delivers long term reliability and lower total cost of ownership. Weba chutes are lined with a range of wear-resistant materials including ceramics, hardened steel, rubber and polyurethane, carefully selected and placed based on operating demands. Their modular construction also allows for easier maintenance and faster liner replacement, reducing both downtime and safety risks for maintenance teams.

Another important advantage is the company’s ability to retrofit chutes into existing structures without major civil works. “We often conduct on-site assessments that include 3D scanning, enabling us to custom-design a chute that slots into the available space while solving longstanding issues like blockages, uneven wear or excessive dust,” Baller explains.

Across its extensive reference base, Weba Chute Systems has delivered results in some of the most challenging conditions, from underground platinum mines with sticky ore to high tonnage iron ore operations running 24/7. In one example at a large copper mine, a Weba chute reduced liner changeouts from every three weeks to just twice a year, delivering substantial savings on maintenance and production stoppages.

Baller emphasises that a chute should not be seen as a standard commodity, but rather as an integral part of an optimised materials handling system. “It is easy to overlook the transfer point until it starts failing but by then the damage is already done, both in terms of cost and productivity. At Weba Chute Systems, we engineer for performance, longevity and value. That’s why we say with confidence - not all chutes are created equal.”