Global engineering specialist Koch Solutions is delivering all-electric, sustainable material handling solutions, from stackers to reclaimers, designed for decades of reliable service.
When Koch Solutions designs a machine, every structural, mechanical, electrical, and automation component must work in harmony. Even small changes can trigger a ripple effect across the design.
For example, replacing a ladder with stairs and a platform adds weight, which may require upgrading the hydraulic luffing cylinders. This, in turn, demands larger pumps, electric motors, and switchrooms, with each modification compounding the machine’s size, weight, and cost.
With mining companies seeking both cost efficiency and reduced carbon footprints, design optimisation is critical.
Original equipment manufacturer (OEM) head of sales Luke Bennett told ABHR that, without careful oversight, incremental changes can spiral.
“As an OEM, we know where to draw the line so we can deliver a machine that meets the project’s requirements safely, delivers the tonnes needed, and stays within budget. A machine that might start at 1500 tonnes can end up significantly overweight adding millions to the cost of the machine and the clients required infrastructure.”
From collaborative design to advanced automation, Bennett said OEM partnerships are delivering measurable gains in productivity, safety, and sustainability.
Sustainable stackers and reclaimers
Koch Solutions’ stackers and reclaimers are typically designed for a minimum 25-year service life. Over that time, mining technology, operational needs, and environmental, social, and governance (ESG) priorities can shift dramatically. Close OEM collaboration ensures clients can upgrade equipment for improved throughput, energy efficiency, and safety.
“Technology changes, ESG priorities emerge, and automation becomes more advanced,” Bennett said.
“We partner with specialist suppliers around the world to integrate the latest solutions into existing assets.”
Pre-study phases involve working with clients to determine the optimal machine size, configuration, and efficiency strategy — whether that means a single high-capacity unit or multiple smaller machines.
By refining operational programming and reducing inefficiencies, Koch Solutions can increase utilisation rates from around 70 per cent to 80 per cent and beyond, translating into significant performance upside as well as cost and energy savings.
Productivity gains through smarter design
Productivity often stems from smart engineering rather than raw power. Bennett shared a commissioning example where a new machine seemed underpowered. The culprit was the bucket tooth design, which increased cutting resistance.
By using computer-aided simulations to redesign the tooth, Koch Solutions reduced friction and boosted performance without increasing motor size.
“We can now apply that design across other machines and sites,” Bennett said. “It’s a great example of the iterative process that only an OEM with both design and servicing capabilities can deliver.”
This approach, known as total lifecycle asset management, focuses on baselining current performance and continuously improving, whether that means extending wear life, reducing manual intervention, or implementing safer inspection methods.
Building smarter, connected systems
Automation and digital integration are making supply chains more intelligent. Koch Solutions’ machines connect mine stockpiles with export logistics, and new technologies enable precise ore tracking from pit to ship.
“With today’s systems, a client can request a specific grade and moisture content from a stockpile quadrant, and the machine will automatically reclaim exactly what they need,” Bennett said.
In Australia, most assets now operate without on-board operators, apart from shiploaders, which are transitioning towards semi-automation.
“Even with a human in the loop, the optimal hatch-filling method is automated, with the operator mainly there for safety oversight,” Bennett said.
Bennett said that OEM-led collaboration is about much more than delivering machinery.
“It’s an iterative process that starts on day one and continues through the machine’s entire lifecycle. When you work with an OEM, you’re getting not just a machine, but the knowledge, partnerships, and experience that ensure it delivers value for decades.”