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Case Studies

TS Global partners with customers to solve complex conveyor and material-handling challenges across mining, quarrying and bulk-handling operations. These case studies demonstrate how our practical, engineered solutions improve safety and performance while reducing maintenance and downtime.

Explore the real problems we’ve solved and the measurable results we’ve delivered.

Extreme tonnage, high belt speeds and abrasive operating conditions were accelerating primary scraper blade wear at a major Western Australian iron ore port. The site required a solution capable of lasting approximately 17 weeks between planned shutdowns and reducing mid-cycle maintenance.

Following an assessment of the application, TS Global engineered the Mega XHD polyurethane primary scraper. The system achieved the targeted 17-week service interval while maintaining consistent cleaning performance and enabling quicker, safer servicing through its modular cartridge design. Following the successful trial, the port began introducing the system to a second conveyor.

Persistent product build-up and carry-back on the CV2206 conveyor at Rio Tinto’s Hope Downs 4 operation were contributing to premature belt, roller and pulley replacement, extensive clean-up requirements and manual-handling risks during belt-cleaner servicing.

TS Global installed retractable H-Type and P-Type spring-tensioned belt cleaners, delivering an immediate improvement in belt cleanliness. The cartridge-based retractable system also reduced manual handling, made inspection and adjustment easier and enabled belt-cleaner servicing to be completed in approximately 30 minutes.

Traditional steel hard skirts were causing ongoing conveyor belt damage, frequent replacement requirements, material spillage and dust issues at a major Western Australian mining operation.

TS Global replaced the steel liners with a custom-engineered polyurethane hard-skirt system designed to protect the belt and improve material containment. Following installation, the site reported zero belt damage from skirt interference, improved dust suppression, no spillage issues and reduced maintenance requirements.

An outdated belt-cleaner mounting arrangement was placing additional load on the head pulley bearing housing while limiting cleaning performance and making maintenance more difficult.

TS Global installed a new 1200BW belt-cleaning system mounted on movable cheek plates, along with two spring-tensioned secondary cleaners profiled to the worn belt. The upgrade reduced load on the bearing housing while improving belt cleaning, serviceability and maintenance efficiency.

Rio Tinto sought a safer, lighter alternative to traditional belt-cleaner components to reduce operator fatigue and manual-handling risk during installation and refurbishment.

A trial of TS Global’s lightweight composite P cushions at the Dampier 12E conveyor reduced the scraper weight by 5 kg while delivering equivalent cleaning performance and service life after 30 weeks in operation.

Inadequate belt support and an outdated skirting system were causing damage to the client’s new conveyor belt, material spillage and excessive carry-back.

TS Global designed and installed a customised retractable roller impact bed and skirting system, along with an upgraded primary cleaner. The solution improved belt support and tracking while significantly reducing spillage and carry-back.