Material cleanup in the mining industry: Removing the complexities and safety issues with new tech

In the mining and quarrying sectors, efficiency in material cleanup during the crushing and conveyor processes is critical. It inevitably impacts output, number of downtimes, resource allocation, worker safety, and operational costs.
Conventional means of removing waste under conveyors have challenged foremen and production supervisors for decades. However, new innovations in material handling heavy-duty equipment, like Movex Innovation’s MINIDOZER 27″ and MINIDOZER 48″ ultra-compact mini loaders, are proving valuable assets to overcome the many complications associated with legacy techniques. Let’s explore them in more detail.

Managing materials in mines and quarries is renowned for being difficult due to constant spillage and blockages. Conveyor systems frequently experience material overflow, particularly at transfer points. Traditionally (and still to this day!), to remove the debris, multiple employees were required to manually remove dust, rocks, and debris using shovels. This gruelling task could take hours or days because the conveyors had to be stopped so that the workers could safely carry out the material cleanup.

That meant tens of thousands of dollars lost in output each hour.

Because of constrained timelines, some maintenance teams would delay the removal of spilled material beneath conveyor systems until it accumulated to the point of causing equipment breakdowns, exacerbating downtimes to extend over several days or weeks—not to mention the unplanned costs and production delays.

Furthermore, manual handling poses safety risks, as workers operate in hazardous conditions, often in extreme heat. Musculoskeletal injuries from repetitive motions or bumping into the conveyors, slips and falls due to uneven surfaces, and exposure to potentially harmful substances inevitably lead to higher absenteeism and insurance premiums.

Other mining and quarry operations sometimes used water hoses; apart from being unsustainable, this technique could not be used for certain materials, like iron ore, which is typically recovered dry.

So, is there a better way than the shovel or water hose?

Some mines think skid-steer loaders, also known as skid loaders, skidsteers, or SSL, are the solution. Indeed, they can be a viable alternative. But there are a couple of aspects to remember when dealing with skid loaders.

For one, many of them are still fuel-powered. With today’s gas prices, that can cause a real dent in a company’s bottom line. They also do little to reduce noise pollution—damaging workers’ health yet again—and GHG emissions.

Other companies have introduced electric and remote-controlled skidsteers, but their bulky designs make it difficult to maneuver under the hard-to-reach spaces typically found under a conveyor system. Many operate either on standard wheels or caterpillar wheels; however, in both cases, the equipment can be hard to turn in tight places, and the traction is not ideal on rugged terrains.

Movex Innovation’s MINIDOZERs have the lowest profiles in the industry. Mounted on caterpillars that can be independently operated, they can easily turn in narrow passages, and their grip on all types of surfaces makes them exceptionally stable.

Luckily, another proven solution on the market tackles these problems as well.

Movex Innovation’s electric, remote-controlled MINIDOZERs are proving to be game changers in finally resolving the difficulties associated with spillage removal in mines and quarries. Requiring only one operator, these MINIDOZERs can be maneuvered with a simple wireless controller with two ultra-precise and responsive joysticks—up to 300 ft. away from the conveyor systems. Another key advantage: the operator does not need to have any special certifications, making the equipment accessible and easy to use for a broader range of employees.

Their ultra-compact design allows them to operate in extremely narrow, confined spaces where other taller equipment cannot reach. In fact, MINIDOZERs can remove spillage without ever stopping the conveyor systems. Their low profiles have been specifically developed so that the machines can clean under conveyors. Featuring the biggest bucket capacity for their sizes, the operator can, therefore, safely load a high volume of material under the lowest structure.

Worker health and safety come first with Movex Innovations’ MINIDOZERs. Apart from allowing teams to ditch the shovel work, the equipment is electric, emitting zero emissions, with the added benefit of slashing fuel costs.

Regarding battery life, the MINIDOZERs can run for up to 12 hours on a single charge. For operations requiring continuous use, additional battery packs can extend the runtime by another 12 hours, allowing the equipment to run 24/7. Battery changes are straightforward and can be completed in just five minutes with a forklift, ensuring minimal disruption to operations.

A common concern for battery-operated equipment is its performance in extreme temperatures. However, the MINIDOZERs can get the job done anywhere and in any harsh conditions, from the freezing temperatures of Alaskan and Canadian mines to the intense heat of Australian operations. Unlike chemical-based batteries, which can lose efficiency in temperatures as low as -22 to -40 degrees Fahrenheit, our batteries remain reliable.

Service and maintenance questions often arise when mines and quarries procure new equipment. However, Movex Innovation’s MINIDOZERs are built to be maintenance-free, guaranteeing minimal downtime and hassles when properly used.

All parts are easily accessible, simplifying any untoward repairs. The company even offers remote assistance to support maintenance teams whenever needed. For those who prefer a more hands-on approach, Movex Innovation provides comprehensive training to ensure crews are fully equipped to maintain the MINIDOZERS.

Movex Innovation’s team of engineers are also ready and available to custom engineer MINIDOZERS to resolve specific material cleanup challenges.

Aluminum smelters are unique environments. And Movex Innovation has MINIDOZERs tailored to their needs. The MINIDOZER AL-27, MINIDOZER AL-39 and MINIDOZER AL-48 are a tremendous aid for material cleanup.

In addition to being able to withstand extreme temperature fluctuations, these units can take into account smelters with high concentrations of suspended particle matter and can function in areas with electromagnetic fields exceeding 300 gauss. They can be operated with the controller remotely up to 100 ft.

Movex Innovation’s MINIDOZERs have been successfully integrated into operations by notable clients, including VALE, Rio Tinto, BHP, Kinross, and Centura Gold. These industry leaders trust the MINIDOZERs for their robust performance, reliability, and ability to address the mining and quarry sectors’ specific spillage removal.

By combining unmatched efficiency, safety, low maintenance, and robust performance in extreme conditions, the MINIDOZERs support operations in achieving their throughput goals while minimizing downtime and operational costs. As the industry evolves, adopting advanced technological solutions like the MINIDOZERs will be essential for maintaining competitiveness and viable business growth.