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ECORA Solutions

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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.

28/10/2026

When Carryback Is Annualised, the Number Changes the Conversation.

In this iron ore operation, carryback and the downtime associated with cleaning were costing an estimated 150,000 tonnes of production a year. Presented as a percentage of a single load, carryback reads like a housekeeping issue. Presented as annual tonnes not delivered, it becomes a production line item that competes with capital projects for attention.

Following implementation, the operation recorded a 56% reduction in carryback and a 50% reduction in downtime, together with lower fuel consumption and reduced cleaning cost. None of that required additional trucks, additional routes or a change to the mine plan. It came from material releasing properly at the point of discharge, on equipment that was already in service.

27/10/2026

Consumption Is an Engineering Question, Not a Guess.

As a working reference, one litre of ECORA Eco Release Agent treats approximately 25 square metres of surface. That figure is a starting point rather than a specification, because the volume and frequency actually required are set by the geometry of the asset, the condition of its surface, the characteristics of the ore, the moisture present and the operating cycle it runs.

This is why the trial protocol begins with saturation coats. The first applications seal the micro-gaps, scratches and defects in the steel; once the surface is sealed, maintenance applications are considerably lighter. Performance tends to peak after several weeks of continuous application, and because the operating variables shift over time, the protocol is periodically recalibrated to hold performance and protect the return on investment. Knowing what you will actually consume is part of knowing what the solution will actually cost.

26/10/2026

Wagon Carryback Is Measured in Minutes, Then Multiplied.

In this iron ore operation, an average of 33% of the material was adhering to the wagons, and the average unloading time was 2 minutes and 17 seconds per wagon. On a circuit that runs continuously, a delay of that size at the unloading station is not an isolated event — it repeats across every wagon, every rake, every day, and it propagates back through the rail cycle and forward into port operations.

Following the implementation of ECORA, the average unloading time fell to 1 minute and 43 seconds per wagon, with a lower dependency on manual intervention and added protection against oxidation of the wagon surface. Around half a minute per wagon sounds small until it is multiplied by the number of wagons moved in a year. For critical rail corridors carrying ore from mine to port, better material release converts directly into higher throughput and better use of the existing fleet.

22/10/2026

Bauxite Handling Is Difficult at Both Ends of the Country.

In northern Australia — Cape York, Weipa and Gove — tropical humidity, heavy seasonal rain and cyclonic weather raise bauxite moisture and adhesion, and clay-rich fines form a sticky mass on buckets, trays, hoppers and chutes. In the Darling Range in the south-west, the pattern is seasonal rather than constant: fine dust accumulates through the hot, dry summer, then combines with winter rain or residual moisture to form a compacted, clay-like layer across the equipment feeding the refinery systems.

The climates are opposite. The handling problem is the same, because both regions combine shallow and laterally extensive deposits, long haul and transfer distances, a high proportion of fines and clay minerals, strong sensitivity to moisture and progressive compaction on steel surfaces. In simple terms: surface roughness plus fine particles plus moisture plus compaction equals progressive build-up. Reducing adhesion at the surface addresses the mechanism rather than the weather.

21/10/2026

The Right Application Method Depends on the Asset.

The ECORA Eco Release Agent is the same in every deployment. How it reaches the surface is not. ECORA Trial applies the product manually under a controlled protocol to establish the baseline, measure the benefit and define the long-term solution. ECORA Jet is a manually operated, highly mobile option suited to spot treatment, restricted access and lower application frequencies, in any environmental condition.

ECORA SmartJet is semi-automated and relocatable, with sensors and an electronic control panel, for medium to large fleets that need consistent application built into an existing routine. ECORA AutoJet is fully autonomous and fixed, with real-time monitoring and no operator required, designed for large-scale operations running 24/7. Every deployment is supported by engineering services and data, so the equipment, consumable rate and monitoring plan are matched to the asset rather than the other way around.

20/10/2026

A Trial Is Only Useful If It Is Measured.

Every ECORA trial begins by establishing an operational baseline, because a change you cannot quantify is a change you cannot justify. The metrics are selected with the site according to the equipment, the commodity and the objectives — tonnes moved per shift, equipment availability, downtime caused by build-up, cleaning hours per month, equipment cycle time, throughput, payload efficiency, cost per tonne moved, safety interventions avoided, and return on investment with the associated payback period.

The comparison is then made on recorded site data rather than visual observation alone. At the end of the trial, ECORA provides a performance report comparing the baseline and treated periods, quantifying the benefit in operational, maintenance, safety and financial terms, and recommending the application system, consumable rate, maintenance approach and monitoring plan best suited to the operation. The objective is not to demonstrate that something looks cleaner. It is to show, in your own numbers, what changed.

19/10/2026

Coal Does Not Travel in a Straight Line.

Between the mine face and the vessel, coal passes through truck trays, feeders, crushers, transfer chutes, conveyors, hoppers, silos, stackers, reclaimers, train loading facilities and rail wagons. Every one of those transfers is a place where material can adhere, accumulate and restrict flow. Truck tray carryback, crusher feed hopper build-up, transfer chute blockages, belt carryback, bin hang-ups, stacker carryback, train load-out build-up, wagon carryback and ship loader chute build-up are all the same underlying problem appearing in a different piece of equipment.

Coal is one of the most difficult bulk materials to handle because of its variable moisture content, particle size distribution, clay contamination and the fines generated during crushing and handling. Those characteristics increase adhesion between the coal and the steel, particularly in wet or humid conditions. By reducing that adhesion at the surface, ECORA helps keep material moving through the transfer points that decide overall plant throughput.

15/10/2026

Preventive or Reactive?

Most operations already have a way of dealing with build-up. The question is whether that method prevents material from adhering, or restores flow after it has already accumulated.

Preventive controls reduce adhesion before build-up develops: low-friction and wear liners, design modifications that improve flow geometry, and ECORA, which reduces adhesion at the steel surface itself. Reactive controls restore flow once material is already there: air cannons that break bridging in chutes and hoppers, mechanical vi*****rs, water washing and sprays, and manual or mechanical cleaning after isolation. Conveyor belt cleaners sit in both categories.

ECORA is one of the few options that works on both sides. It reduces initial adhesion and, following application and operation, assists in releasing build-up that has already formed — and it works independently or alongside the controls already installed on site.

14/10/2026

Dry Conditions Do Not Mean Clean Equipment.

Material build-up is often assumed to be a wet-season problem. It is not. These images were taken through a single shift in the Western Australian Goldfields, in dry, high-temperature conditions, and they show carryback progressively anchoring to the tray of an untreated CAT 777 between 07:44 and 10:38.

Even in dry climates, moisture reaches the material through ore geology, groundwater, dust suppression systems, processing activities, rainfall events and stockpile management. When that moisture meets fines, clay content and the natural roughness of a steel tray, the first layer adheres — and once it does, further material compacts on top of it.

Fines plus residual moisture plus clay content plus surface roughness plus compaction equals build-up and carryback. The consequences follow the same pattern everywhere: reduced effective payload, restricted chute and hopper cross-section, higher cleaning demand and water consumption, and lower equipment availability.

13/10/2026

46% Lower Cost Per BCM.

Carryback is usually discussed as a cleaning problem. Measured properly, it is a cost-per-unit-volume problem. In a seven-day controlled trial on a Western Australian overburden operation running a fleet of 10 CAT 777 trucks, ECORA was applied daily to two haul trucks and to the hydraulic excavators, while baseline and treated performance were recorded side by side.

The measured outcome was an estimated 46% reduction in total operational cost per BCM. That figure comes from three compounding effects: bucket passes falling from 13 to between 6 and 8, trips per shift rising from 35 to 40 up to 45 to 52, and cleaning downtime of 30 to 45 minutes per event being eliminated. Together they produced an increase of 50% to 60% in the volume of material moved each day, using the same fleet, the same routes and the same shift pattern.

The cost was not reduced by cutting anything. It was reduced by moving more with what was already on site.

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