Equipment automation is taking “centre stage” in original-equipment manufacturer (OEM) Astec Africa’s product offering to mining clients across Africa, says capital sales business line manager Calvin Fennell.

He says the company’s TRAC10 system is a key example of how digital solutions are reshaping mine operations. The TRAC10 is a standalone control platform designed for Astec Titan-Series cone crushers, which enables operators to remotely adjust crusher settings during active production, ensuring consistent throughput and reliable product quality.

“TRAC10 automates liner calibration, monitors wear levels and issues alerts when thresholds are reached, helping clients avoid unexpected downtime,” he adds.

The system records detailed data every two seconds for up to a year, covering lubrication, hydraulic and electrical systems. This historical record supports predictive maintenance and troubleshooting, consequently enabling mines to take proactive measures rather than reacting to equipment breakdowns.

Fennell adds that the platform also allows for remote access through file transfer protocol and real virtual network computing, enabling operators to manage systems from any location.

Astec’s broad suite of digital technologies, outlines Fennell, enable mining companies to reduce downtime, extend equipment life and achieve greater efficiency at scale: “Our focus is on giving clients the ability to operate smarter and more sustainably, particularly in environments where reliability is critical”.

Building on its digital approach, Astec is also positioning itself as a locally embedded OEM with global innovation support.

The company’s Johannesburg-based facility manufactures modular crushing and screening equipment; this local production shortens delivery times, lowers logistics costs and ensures faster technical support for mines and aggregate operations across the region. It also supports the South African economy through job creation and skills development while reducing dependence on imported equipment, adds Fennell.

Cone Crushers

Astec’s Titan cone crushers form another important part of the company’s product range, incorporating hybrid bearing technology that reduces friction and maintenance costs, and improves wear life and uptime for clients.

Modular plants, manufactured in Johannesburg, also feature energy efficient motors and optimised material flow designs that lower power consumption, says Fennell, adding that these innovations respond directly to the high-throughput requirements of African mines while also aligning with sustainability goals.

Flexibility in deployment is another growing priority for mines, particularly in remote locations or phased developments and, in this regard, Astec has expanded local production of screens, and modular jaw and cone crushers to meet such demand.

These container-friendly units are easy to relocate and are backed by responsive technical support, adds Fennell, noting that this flexibility enables clients to scale operations as required, without the delays often associated with traditional fixed infrastructure.

Astec also works closely with clients to address operational challenges such as ore variability, limited access to spares and maintenance delays. The company provides customised plant layouts and integrates automation tools, such as TRAC10, to ensure that equipment runs reliably under demanding conditions.

“By providing both local manufacturing and advanced diagnostic systems, we help clients achieve consistency and performance in environments where downtime is costly.”

Sustainability

Sustainability is embedded throughout the Astec group’s designs, with its equipment incorporating recyclable components, energy efficient motors and emissions reduction systems, while localised production reduces transport-related emissions.

Fennell adds that Astec’s burner control technologies, such as Intelliflex, further optimise fuel use and enhance safety, thereby helping mines meet environmental, social and governance requirements while improving efficiency of thermal industries.