Mines have significantly transformed their approach to crushing and screening in recent decades, increasingly recognising the benefits of flexibility offered by mobile and modular plants. Modern Mining spoke to Pilot Crushtec to explore how these changes are reshaping the sector.
“Today, it is far more common for contractors to handle the crushing and screening on behalf of mining companies,” says Francois Marais, Sales and Marketing Director at Pilot Crushtec. “With a strong focus on reducing loading and hauling costs, strategies like in-pit crushing are gaining traction.”
Marais notes that this represents a clear departure from the large static crushing plants that dominated mining operations three decades ago. Pilot Crushtec played a pioneering role in this industry shift, introducing an expanding range of mobile and modular solutions to support the transition.
Adding to this, Wayne Warren, Africa Sales Manager at Pilot Crushtec, explains that the traditional model required significant investment in fixed infrastructure, which was both costly and time consuming to establish – with returns only realised progressively over the project’s lifespan.
“Our modular crushing and screening units eliminated the need for much of that fixed infrastructure, and the industry soon saw that they could meet production requirements without relying on static plants,” says Warren. “It wasn’t long before others in the sector began emulating our approach, and the success of our designs helped establish a solid foundation for our local manufacturing capability.”
By the 2000s, this shift was well underway with growing adoption of both mobile and modular solutions. Today, Marais notes, the entire processing cycle – from run-of-mine (ROM) to the pre-milling stage – can be efficiently executed using a fully mobile setup.
“A key driver behind the popularity of mobile solutions is the growing trend of mines outsourcing their crushing and screening,” says Marais. “Contractors need to mobilise and deploy equipment quickly and mobile units offer that flexibility. At the same time, volatility in commodity prices adds to the appeal – mines want to ramp up production when prices are high, but without the long-term commitment and overheads of fixed infrastructure should the market turn.”
Warren underscores the importance of maximising return on investment in today’s mining landscape, where securing finance for a mobile or modular plant – capable of generating immediate returns – is far more achievable than funding static infrastructure that may take months or even years to become operational.
“A mobile solution delivers real value not just to the contractor, but also to their client and the financier,” he explains. “Its responsiveness aligns with the time sensitive demands of modern mining, and its versatility reduces risk, especially if a contract ends earlier than expected, as the equipment can simply be redeployed to another site.”
As demand for more flexible solutions has increased, so too has Pilot Crushtec’s range of offerings. The DynamiTrac J100S compact mobile jaw crusher – with an integrated oversize screen – is ideally suited for junior miners, small-scale contract crushers and even construction material recycling. It is also available in a modular version, which can be easily relocated on site.
“Our DoppiaTrac is a track-mounted self-driven machine designed for the feeding, crushing and stockpiling of medium to hard bituminous coal,” adds Warren. “It features a purpose-built 3636 double drum roll, making it highly effective for coal applications.”
Pilot Crushtec’s range has evolved to such a degree that its flagship model – the versatile TwisterTrac – is now in demand globally, particularly in Europe. Designed for producing sand and fines, and for improving aggregate quality, the track-mounted self-driven TwisterTrac is ideal for tertiary and quaternary crushing applications. It features a purpose-designed vertical shaft impact (VSI) crusher for optimal performance.
Adding further value to its offering, the company also supplies Mobi Light freestanding mobile lighting towers. These units require no external power source, can be easily towed and are quick to install on site, making them a practical solution for remote or fast-moving operations.
As the southern African distributor for global crushing and screening leader Metso, Pilot Crushtec also supplies Metso’s renowned range – comprising Nordwheeler portable units, Nordplant modular solutions and the premium Lokotrack mobile plants. These offerings complement Pilot Crushtec’s in-house range, giving customers a broad selection tailored to their specific application needs and component preferences.
“This partnership gives us a complete suite of mobile and static crushing and screening equipment across all stages – primary, secondary, tertiary and quaternary,” says Marais. “Our solutions support production rates from 30 tonnes per hour to over 500 tonnes per hour, across a wide spectrum of applications including mining, quarrying and recycling.”
Ongoing industry efforts to reduce energy consumption in crushing and screening equipment have led to notable advancements in efficiency. These include the introduction of dual power machines that can operate on electrical grid power when available. “In fact, our TwisterTrac was one of the first models to offer a dual power option, as far back as eight years ago,” notes Warren.
Additional gains have come from high efficiency electric motors and the reduction of hydraulic and friction losses throughout the crushing and screening train.
With such a broad equipment range, Pilot Crushtec is able to take a holistic approach to each customer’s requirements, using specialised software to simulate plant design and layout. “It is not just about finding a plant that fits the job,” says Warren. “It is about guiding the customer to a solution that protects their investment – both now and into the future.”
This long-term value is supported by Pilot Crushtec’s 24 hour technical support and robust parts availability, with R160-million worth of stock on hand to minimise downtime. Equally important are the company’s remote monitoring systems which track equipment usage, detect anomalies and predict wear levels.
“This capability allows us to work with customers to develop predictive maintenance strategies that keep operations running smoothly and improve overall returns,” he concludes.
In an industry where margins are tightening and operational agility is non-negotiable, Pilot Crushtec’s innovations are more than just engineering achievements – they’re enablers of strategic advantage. By driving down setup costs, accelerating time-to-production, and allowing mines to scale capacity in real time, these mobile and modular solutions help mining houses and contractors navigate uncertainty with confidence. Whether it’s responding swiftly to price spikes or reallocating equipment to high-yield projects, customers gain the flexibility to maximise profit and minimise risk, making every ton count.
