ECORA Solutions

03/09/2026

Carryback Costs More Than Lost Payload.

When material remains in the truck tray after discharge, the immediate loss is reduced effective payload. However, the operational impact continues throughout the return cycle, as the truck consumes fuel carrying retained material that no longer contributes to production. Across repeated cycles and multiple trucks, these small losses can accumulate into a significant reduction in fleet efficiency.

The cost increases further when an excavator is diverted from loading duties to remove compacted material from the tray. Both production assets are taken offline, equipment availability is reduced and the haul cycle is disrupted. By improving material release at the source, ECORA helps reduce carryback, minimise cleaning interventions and support more productive use of the existing fleet.

To learn how ECORA can improve the performance of your operation, contact us at [email protected] or visit www.ecorasolutions.com.

          

02/09/2026

02/09/2026

Improving Feeding Velocity and Reducing Blockages.

In this operation, material build-up inside the chute was restricting flow and forcing the feeding velocity to be reduced to keep the circuit running. Frequent material aggregation created recurring blockages, resulting in repeated intervention, cleaning activity and production delays. What should have been a continuous transfer point became a regular constraint on throughput and operating stability.

Following the implementation of a customised ECORA solution with a four-nozzle application arrangement, the operation achieved a 30% improvement in feeding velocity. The result was improved productivity, reduced cleaning-related downtime and less dependence on manual intervention to keep material moving. By improving material release at the critical contact points, ECORA helped restore a more stable and efficient flow path through the chute.

To learn how ECORA can improve the performance of your operation, contact us at [email protected] or visit www.ecorasolutions.com.

          

01/09/2026

More Production Does Not Always Require More Equipment.

At large-scale mining operations, productivity is often discussed in terms of fleet expansion, additional capital and new infrastructure. However, material build-up can quietly reduce the effective capacity of trucks, excavators, chutes and other assets already in service. Incomplete discharge, longer cycles and repeated cleaning stops mean existing equipment is not always delivering its full productive potential.

Improving material flow can unlock additional capacity without changing the fleet. By reducing adhesion and supporting cleaner discharge, ECORA helps increase productive time, improve cycle consistency and make better use of existing assets. The opportunity is not simply to add more equipment, but to help the equipment already on site perform more effectively.

To learn how ECORA can improve the performance of your operation, contact us at [email protected] or visit www.ecorasolutions.com.

          

31/08/2026

Improved Productivity Through Better Material Release.

In this operation, carryback levels of approximately 5% to 10% were extending unloading time and disrupting the haul cycle. Operators relied on repeated mechanical manoeuvres and manual cleaning to release retained material, increasing downtime, maintenance demand and the risk of damage to the truck body and associated components.

Following the implementation of the ECORA automated gantry solution, the operation recorded a 23% reduction in cycle time, together with fewer cleaning interruptions and lower maintenance requirements. More consistent discharge increased the overall volume moved under the same operating conditions, demonstrating how better material flow can improve productivity without adding more trucks or changing the fleet.

To learn how ECORA can improve the performance of your operation, contact us at [email protected] or visit www.ecorasolutions.com.

          

27/08/2026

Tomorrow we’re hosting the next ECORA Operational Excellence Series, focused on practical mining challenges and real opportunities to improve operational performance.

If you work in Operations, Reliability, Maintenance or Operational Excellence, join us for a practical discussion on productivity, equipment availability and material flow — with time for questions and shared experiences.

Register through the ECORA Solutions page on LinkedIn and join us tomorrow.

27/08/2026

Cleaning Removes Build-Up. It Does Not Prevent It.

High-pressure water cleaning is often used only after material adhesion has already become an operational problem. By that stage, the truck must be stopped, isolated and removed from productive service, while personnel, water and maintenance resources are redirected to restore the tray. Repeated interventions can increase safety exposure, create runoff-management requirements and add significant labour demand across the fleet.

Preventing adhesion before build-up becomes established is a more sustainable operational approach. ECORA helps reduce the need for repeated cleaning by improving material release at the tray surface, supporting lower water consumption, fewer manual interventions and greater equipment availability. The result is a safer, more stable and more productive haulage operation.

To learn how ECORA can improve the performance of your operation, contact us at [email protected] or visit www.ecorasolutions.com.

          

26/08/2026

50% Reduction in Cleaning-Related Downtime.

In this operation, 63-tonne trucks retained an average of approximately 400 kg of material per cycle. Across the fleet and operating year, this represented an estimated 115,200 tonnes of material carried back instead of being discharged at the intended destination. Cleaning interruptions also created substantial production losses, while increasing water use, manual intervention and operating costs.

Following the implementation of the ECORA automated gantry solution, build-up material was reduced by 66% and cleaning-related downtime by 50%, as measured under site conditions. The operation achieved a direct return on investment from the additional volume moved alone, with further benefits from lower fuel consumption, reduced cleaning costs and less reliance on water and manual intervention. The result was improved material flow and greater productivity from the existing haulage fleet.

To learn how ECORA can improve the performance of your operation, contact us at [email protected] or visit www.ecorasolutions.com.

          

25/08/2026

3 days to go — this Friday!

Don’t miss the next ECORA Operational Excellence Series. Join us for a practical discussion on real mining challenges and operational improvement.

Register through the ECORA Solutions LinkedIn page.

25/08/2026

Carryback Costs More Than Lost Payload.

Retained material reduces the effective capacity of the truck and adds unnecessary weight to the return cycle. That means fuel is consumed transporting material that should already have been discharged, while less new material is moved on the next load. Over repeated cycles, even relatively small amounts of carryback can create a measurable loss across the fleet.

The impact increases further when cleaning requires an excavator or other production asset to assist with material removal. These interventions take equipment out of service, reduce availability and interrupt the haulage cycle. By improving material release, ECORA helps reduce carryback, minimise cleaning demand and support more productive use of the existing fleet.

To learn how ECORA can improve the performance of your operation, contact us at [email protected] or visit www.ecorasolutions.com.