Integrating complex equipment into the critical crushing and screening stages of comminution is rarely straightforward which is why Sandvik Rock Processing strongly supports an engineered-to-order (ETO) approach.

According to Tarynn Yatras, Vice-President Sales Area Africa for Sandvik Rock Processing, the ETO model enables the company to design plant configurations around the specific operating conditions and requirements of each mine, rather than an “off-the-shelf” solution.

Yatras notes that mines are increasingly recognising the value of ETO solutions which allow custom-designed systems for crushing plants that are developed to meet the specific operational, material and site requirements of individual customers – particularly for complex mining and large quarry applications. Sandvik Rock Processing is well positioned to provide and deliver fully integrated ETO solutions.

“Our ETO offering allows us to deeply integrate our engineering expertise using site-specific knowledge,” she explains. In a typical installation, equipment such as jaw crushers, cone crushers, screens and rock breakers can be seamlessly combined from Sandvik Rock Processing’s extensive product range.

Site-specific challenges can also be addressed early in the design phase. Factors such as ore abrasiveness, required throughput, plant layout and operational constraints all influence equipment selection and circuit configuration.

“Particular challenges like space restrictions or unusual elevations – common in brownfield operations - may also need to be accommodated,” she says. “Complex multi-stage crushing arrangements may be required, with careful fine-tuning of flowsheets.”

Digital simulation tools play a key role in identifying the optimal configuration. By modelling different plant layouts, engineers can test alternative flowsheets and predict circuit performance before implementation.

“We help customers make the most of the planning stages to identify the optimal design,” Yatras explains. “In some cases, it may be necessary to evaluate 15 or 20 different flowsheets before arriving at the most effective solution.”

Yatras is quick to point out that Sandvik Rock Processing is not an EPCM house and the company remains focused on delivering crushing and screening product solutions.

Another advantage of the ETO model is improved accountability. When multiple OEMs supply individual components, identifying the root cause of performance issues can be challenging. An integrated ETO solution reduces this risk by providing the customer with a single point of responsibility.

“Ultimately, the goal is to ensure the plant delivers consistent performance throughout its lifecycle, in line with design expectations,” Yatras says. “While simulations and design expertise provide a strong starting point, ongoing monitoring and optimisation remain essential.”

By controlling the quality of the design, equipment and installation within the ETO solution, Sandvik Rock Processing can also provide process guarantees to customers - an important element in de-risking projects and supporting long-term plant uptime.