In this article, you will learn how SPX FLOW Mixers helped increase mining operations uptime and profitability.  A global mining company recently faced a significant challenge with their aging fleet of mixing gearboxes, essential components in their extraction processes. Frequent unplanned downtimes and long repair times were hampering productivity, leading to considerable losses. The mining industry, especially in the precious metals sector, relies heavily on efficient and reliable equipment to ensure seamless operations. They needed a better solution.

The Challenge: Aging Mixers and Long Downtimes

For this mining company, the mixers that had once been dependable were now obsolete, with the original supplier no longer offering support or parts. To keep these essential mixers running, they had to rely on local repair facilities that took over 20 weeks to service the gearboxes. Not only were the repairs slow, but they were often of poor quality, further reducing the time between repairs. The entire operation suffered from lengthy and frequent downtimes, significantly impacting production.

SPX FLOW's Solution: A Tailored Approach

To address these problems, the company turned to SPX FLOW Mixing Solutions, experts in industrial mixer repair and modernization. SPX FLOW introduced their Mixer Modernization and Reliability (MMR™) Program, a comprehensive service designed to assess and modernize aging equipment.

• Comprehensive Health Assessment: SPX FLOW began by conducting a detailed evaluation of the company's critical assets, determining what upgrades and repairs were needed to improve efficiency.
• Reverse Engineering: Recognizing that the original gearbox supplier was no longer in business, SPX FLOW reverse-engineered the obsolete parts, enabling the manufacture of a spare unit. This allowed the company to rotate gearboxes, ensuring that necessary repairs could be done during scheduled outages rather than unscheduled ones.
• Stocking Plan for Rebuild Kits: Additionally, SPX FLOW developed a tailored stocking plan that included full rebuild kits. This strategic move reduced repair lead times from an unbearable 20 weeks to a more manageable 8 weeks, drastically improving equipment availability.
• Premium Repair Services: Their premium Inspect & Repair program, which included state-of-the-art failure analysis and CMM validation, ensured high-quality repairs with a three-year warranty—significantly increasing confidence in the equipment's reliability.

The Result: Increased Efficiency, Reduced Downtime, and Long-term Success

Seven years after implementing SPX FLOW's services, the mining company saw outstanding results. The modernized mixers, now part of a well-maintained rotation plan, experienced fewer breakdowns and longer periods between repairs. As a result, unplanned downtime was dramatically reduced, leading to an increase in productivity and overall profitability.

The partnership with SPX FLOW continues to thrive, with the company utilizing the MMR, inventory stocking, and Inspect & Repair services across multiple sites. By addressing the unique needs of this mining operation, SPX FLOW has helped ensure that the company remains competitive, efficient, and profitable in a demanding industry.

Conclusion: Future-Proofing Mining Operations

For any mining company facing challenges with aging or obsolete equipment, SPX FLOW offers proven solutions that go beyond simple repairs. Their comprehensive assessment, reverse engineering, and modern repair processes provide long-term reliability and increased operational efficiency. With reduced lead times, better repairs, and proactive asset management, SPX FLOW helps mining companies future-proof their operations and maximize profitability.