ECORA Solutions

ECORA Solutions ECORA Solutions helps Australian mines reduce carryback, build-up material and downtime.

We improve material flow and equipment performance on haul trucks, excavators, crushers, chutes, conveyors and rail wagons with eco-friendly surface technology.

When Bauxite Sticks, Productivity Suffers.Bauxite operations present some of the most demanding material handling condit...
08/07/2026

When Bauxite Sticks, Productivity Suffers.

Bauxite operations present some of the most demanding material handling conditions in mining. High moisture content and clay-rich material create strong adhesion forces that cause material to stick aggressively to truck bodies. Once an initial layer of material is established, it becomes increasingly difficult to remove, accelerating carryback, reducing payload efficiency, increasing cleaning requirements, and creating additional safety and operational challenges across the haulage fleet.

In this operation, trucks were experiencing approximately 25% carryback, resulting in significant productivity losses and increased operational risk during unloading. Following the implementation of ECORA's customised solution, carryback was reduced by approximately 90%, dramatically improving material release and flow characteristics. The operation achieved faster loading and unloading cycles, significant reductions in cleaning time, improved payload efficiency, and safer unloading conditions through the reduction of eccentric loading and material release by large blocks. The result was a more productive, reliable, and safer haulage operation capable of moving more material with the same fleet and workforce.

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


Restricted Flow Reduces Throughput. Efficient Flow Increases Production.Material flow restrictions inside silos can crea...
07/07/2026

Restricted Flow Reduces Throughput. Efficient Flow Increases Production.

Material flow restrictions inside silos can create significant bottlenecks across an operation. In this case, material aggregation was repeatedly restricting flow, forcing operators to reduce feeding velocity to maintain stability and avoid complete blockages. The result was reduced throughput, frequent interventions to restore material flow, and increased dependency on operational teams to keep production moving.

ECORA's customised solution was designed to minimise material adhesion and improve flow characteristics within the silo. Following implementation, the operation achieved a 30% increase in feeding velocity, allowing material to move more efficiently through the system while reducing the frequency of cleaning interventions. The improved flow translated directly into higher productivity, reduced downtime, and lower labour dependency, delivering a more reliable and efficient operation.

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


Every Scrape Damages The Tray. Every Scratch creates Future Carryback.Mechanical cleaning of haul truck bodies using exc...
05/07/2026

Every Scrape Damages The Tray. Every Scratch creates Future Carryback.

Mechanical cleaning of haul truck bodies using excavators is a common practice across many mining operations. While it may appear to be an effective way to remove accumulated material, the process often creates a hidden long-term problem. Every impact from the bucket can introduce scratches, gouges, and surface defects into the truck body, increasing surface roughness and creating new anchoring points where material can adhere during future loading cycles.

Over time, repeated scraping accelerates carryback, increases cleaning frequency, and contributes to premature wear of the truck body. Instead of addressing the root cause, the operation enters a cycle of build-up, cleaning, damage, and more build-up. By preventing material adhesion before it occurs, ECORA helps preserve the integrity of the truck body, reduce the need for mechanical cleaning, and maintain efficient material flow for longer periods. The result is improved productivity, lower maintenance requirements, extended asset life, and a safer operation.

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


When Excavators Stop, Production Slows DownExcavators are among the most critical assets in any mining operation. When m...
02/07/2026

When Excavators Stop, Production Slows Down

Excavators are among the most critical assets in any mining operation. When material begins adhering to buckets and key contact surfaces, cycle times increase, payload efficiency decreases, and valuable production time is lost. What starts as a build-up issue can quickly become a bottleneck that impacts the entire mining value chain.

ECORA Solutions helps reduce material adhesion before it affects performance. By creating a protective barrier between the material and the equipment surface, ECORA improves material release, reduces cleaning requirements, and supports more consistent excavator productivity. The result is improved operational efficiency, lower maintenance intervention, and safer working conditions across the operation.

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

Stop Hauling Dead Weight. Start Moving More Product.Material carryback is a major challenge in bauxite operations, parti...
02/07/2026

Stop Hauling Dead Weight. Start Moving More Product.

Material carryback is a major challenge in bauxite operations, particularly in humid environments where adhesion can rapidly accumulate inside truck bodies. In this operation, a fleet of twenty 63-tonne haul trucks was experiencing a minimum of 20% carryback, resulting in lost payload capacity, longer unloading times, and significant cleaning requirements. Each truck required approximately 40 minutes of cleaning using scrapers and water, creating substantial downtime and increasing labour, water, and operating costs.

Following the implementation of ECORA's customised solution, material release improved significantly, reducing carryback and increasing flow velocity during unloading. The operation benefited from higher payload efficiency, reduced dead weight, shorter cleaning times, and lower operating costs across the fleet. In addition, improved load distribution reduced eccentric loading and helped mitigate tipping risks, delivering both productivity and safety improvements. For high-volume haulage operations, these gains translate directly into more material moved, greater equipment availability, and a safer working environment.

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

Every Load Counts. Depending on tray geometry, material characteristics, moisture levels, and loading conditions, some t...
01/07/2026

Every Load Counts.

Depending on tray geometry, material characteristics, moisture levels, and loading conditions, some truck designs experience significant build-up at the rear section of the tray. While often overlooked, even a 5% carryback rate can result in thousands of tonnes of lost productive capacity over time, reducing payload efficiency and forcing operations to transport unnecessary dead weight on every haul cycle.

During our Western Australian trial, trucks with a more square-bodied design were experiencing persistent carryback at the rear of the tray. Following the application of ECORA, material adhesion was progressively eliminated, allowing complete payload discharge and restoring full truck capacity. By removing the dead weight carried across each shift, the operation improved haulage efficiency, reduced cleaning requirements, and maximised the productive tonnes moved per cycle. The result demonstrates that regardless of truck body design, addressing material adhesion at its source delivers measurable operational benefits.

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

Faster Unloading. Higher Productivity. Lower Operating Costs.Even relatively small levels of carryback can have a signif...
01/07/2026

Faster Unloading. Higher Productivity. Lower Operating Costs.

Even relatively small levels of carryback can have a significant impact on haulage performance. In this operation, trucks were experiencing between 3% and 5% carryback, resulting in longer unloading times, reduced productivity, and recurring cleaning requirements. Operators frequently relied on mechanical manoeuvres to dislodge material during unloading, increasing stress on the equipment and contributing to unnecessary wear and maintenance costs.

Following the implementation of ECORA's customised solution, the operation achieved a 23% reduction in cycle time while improving overall productivity and increasing the volume of material moved under the same operating conditions. Reduced carryback minimised cleaning requirements, lowered labour dependency, and eliminated the need for aggressive unloading manoeuvres. The result was a safer, more efficient operation with lower maintenance requirements and improved fleet performance.

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


Faster Unloading. Higher Productivity. Lower Operating Costs.Even relatively small levels of carryback can have a signif...
01/07/2026

Faster Unloading. Higher Productivity. Lower Operating Costs.

Even relatively small levels of carryback can have a significant impact on haulage performance. In this operation, trucks were experiencing between 3% and 5% carryback, resulting in longer unloading times, reduced productivity, and recurring cleaning requirements. Operators frequently relied on mechanical manoeuvres to dislodge material during unloading, increasing stress on the equipment and contributing to unnecessary wear and maintenance costs.

Following the implementation of ECORA's customised solution, the operation achieved a 23% reduction in cycle time while improving overall productivity and increasing the volume of material moved under the same operating conditions. Reduced carryback minimised cleaning requirements, lowered labour dependency, and eliminated the need for aggressive unloading manoeuvres. The result was a safer, more efficient operation with lower maintenance requirements and improved fleet performance.

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


Carryback: The Hidden Cost of Mining Operations.Carryback is often viewed as a housekeeping or maintenance issue. In rea...
01/07/2026

Carryback: The Hidden Cost of Mining Operations.

Carryback is often viewed as a housekeeping or maintenance issue. In reality, it is one of the most overlooked productivity losses in mining operations. Every tonne of material left behind in a truck body, chute, wagon, excavator bucket, or conveyor system reduces the effective capacity of the operation. While the focus is often placed on cleaning the accumulated material, the hidden costs continue to impact production long after the build-up occurs.

Carryback increases fuel consumption by transporting dead weight, reduces payload efficiency, creates additional downtime for cleaning interventions, accelerates equipment wear, and introduces safety risks during cleaning and unloading activities. Across thousands of cycles, these small losses compound into significant reductions in throughput and increases in operating costs. The most effective way to manage carryback is not to clean it faster—it is to prevent it from forming in the first place. By improving material release and reducing adhesion at the source, operations can increase productivity, improve asset utilisation, and create safer and more efficient material handling processes.

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


Increase Rail Throughput. Reduce Cycle Time. In bulk rail operations, even small delays at unloading stations can have a...
30/06/2026

Increase Rail Throughput. Reduce Cycle Time.

In bulk rail operations, even small delays at unloading stations can have a significant impact on overall throughput. Material carryback in ore wagons increases unloading times, creates bottlenecks across the logistics chain, and often requires additional cleaning interventions that reduce asset utilisation. When operations run 24/7, every minute recovered contributes directly to increased productivity and improved supply chain performance.

ECORA Solutions helps rail operators maximise wagon performance by reducing material adhesion and improving material release during unloading. Proven in demanding bulk material handling environments, ECORA can significantly reduce unloading times, increase material movement per cycle, minimise cleaning requirements, and support safer operations. For critical rail corridors moving ore from mine to port, these improvements translate into higher throughput, greater reliability, and more efficient use of assets across the entire value chain.

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

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