Smarter Mining

Starts Here!

Boost material flow without expanding your plant.

Mixed gear? No problem.

One partner. One plan.

Why use

Smarter Mining?

If you want to increase material flow without expanding your plant, you need more than incremental gains – you need a system that reshapes how efficiency is achieved.
Legacy systems, fragmentation, or mixed equipment? For us, that’s not a limitation – it’s a starting point. We upgrade and support both our own systems and products as well as third-party systems. From core components to wear parts – all under one plan, with one partner.
Together, we create an environment where every ton, every kilowatt, and every hour is taken into account – so the process works even more efficiently.

This isn’t just better mining.
This is smarter mining – and this is where it starts.

HPGR / polycom®

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HPGR / polycom®

Apron feeder

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Apron feeder

Tube mills

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Tube mills

Kilns and Drums

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Kilns and Drums

Crusher

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Crusher

polab® laboratory automation

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polab® laboratory automation

Smarter Mining Needs

Smarter Service

Not because there’s a new machine. But because there’s a smarter way to rethink everything between the rock and the return.

It starts with understanding the process – through audits that reveal what really holds back performance. It continues with material testing, so decisions are based on data, not assumptions. Service becomes a strategic asset when it’s built around real conditions in the field. Durability improves when the right parts arrive at the right time – built to last, built to fit. And even complex, mixed systems turn into opportunities when modernization follows a clear path. Every step is connected. Every improvement is made to last.

This isn’t just better support.
 
This is smarter service – 
and here is where it starts!
Download Service Whitepaper
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Our Mining Portfolio

at a Glance

Scope of Services

  • Evaluate the performance of the existing polycom® grinding circuit.
  • Identify operational bottlenecks and mechanical limitations.
  • Determine the maximum achievable throughput.
  • Ensuring optimized operation of the polycom®

Operational investigation to assess and optimize: 

  • Specific grinding force 
  • Power draw
  • Specific throughput and energy input
  • Checking the metal detectors for proper function
  • Any other plant specific operational challenges

Adjustment of the polycom® machine setting:

  • Spring curve parameters 
  • Chute width
  • Hydraulic pressure
  • polycom® internal control loops 

Sampling and particle size distribution analysis: 

  • Sampling for screen efficiency evaluation

Visual inspection of the polycom® units: 

  • Roller wear and condition assessment  
  • Cheek plates check and adjustment 
  • Feed chute dimensions and wear 
  • Overall condition of the machine

Sample preparation and testing:

  • Mineralogical analysis (XRD)
  • Abrasion testing (ATWAL)
  • High-pressure grinding tests (MAGRO)

Determination of:

  • Specific throughput (m)
  • Circulation factor (cf)
  • Specific energy input (Wsp)
  • Comparison of lab vs. industrial performance
  • Evaluation of screen efficiency
  • Identification of system bottlenecks:
  • All results will be summarized in a detailed technical report.
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Trouble shooting
  • Root cause analysis for sudden machine or plant issues
  • Expert evaluation of measurement data and logs
  • Fast localization of weak point(s)
  • Immediate corrective actions, if possible
  • Inspection report with: Concrete solution proposals Recommendations for further steps
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Service package I (SPI) (basic assessment)
  • Assessment of current conditions in a defined plant section
  • Manual sampling and review of operation records
  • Evaluation of key process data
  • Creation of energy and mass balances
  • On-site discussion and summary of results on site
  • High thermal efficiency
  • Lower power consumption
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Service package II (SPII) (advanced study)
  • Detailed report compiling potential optimization measures based on SPI
  • Feasibility analysis of implementation options
  • Assessment of expected impact on process performance
  • Comprehensive material testing campaign at R&D
Get in Contact

Smarter Mining Offerings

Modernizations
Audits
(process / mech.) and Field Services
Spare Parts
Wear Parts
Revamps
Single Machine
Business
HPGR / polycom®
Crusher / Apron feeder
Tube mills
Kiln / Drums
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polab® laboratory automation
Our offerings
Mobile Service Center
Download Service Whitepaper

Get the Whitepaper and get in Contact

Tobias Klegraf

Tobias Klegraf

Nils Hörster

Nils Hörster

Smarter Mining

with the new polycom®

Discover polycom® by thyssenkrupp Polysius – the innovative solution that boosts your material flow without expanding your plant. Enjoy up to 20% energy savings and reduce power consumption in downstream units by up to 50%. With a robust moving floor, optimized cooling distribution, and intelligent process control, achieve higher efficiency within the same installation space.

Experience more performance with less maintenance thanks to durable components and fast on-site service. Switch to smart technology for sustainable success in mining. One partner. One plan. Your solution for increased productivity.

Apron feeder

Apron feeder from thyssenkrupp Polysius offer the ultimate in performance, reliability and cost-effectiveness. You can expect the optimum, customized solution for even the most demanding of jobs. 

Apron feeders are designed for conveying capacities from 200 tph up to 10,000 tph and can be integrated into stationary, semi-mobile or mobile plants. Also available as lightweight construction for silo discharge.

When a feed conveyor is due for repair or refurbishment, thyssenkrupp Polysius provides the expertise and qualified personnel necessary to carry out the required work with precision and reliability. Our specialists are able to engineer and integrate a modern, state-of-the-art apron feeder into existing installations—regardless of the original manufacturer. 

By utilizing original equipment manufacturer (OEM) parts, we ensure consistent quality and long-term durability. This approach not only guarantees technical excellence but also contributes to a significant reduction in maintenance costs over time.

Crusher

Crushing plants across the globe have been in operation for decades, and many are now confronted with aging equipment, rising maintenance costs, and increasing demands for efficiency and sustainability. 

At thyssenkrupp Polysius, we draw on more than 160 years of engineering expertise and a deep understanding of industrial processes to deliver tailored modernization solutions that prepare your machinery for the future. Even obsolete machines can be revitalized through our advanced engineering capabilities and field service offerings, including 3D scanning and on-site execution. Our modernization services extend beyond thyssenkrupp Polysius equipment. With a multi-brand approach, we successfully upgrade and retrofit machinery from other manufacturers as well. 

We provide customized solutions that boost performance, minimize downtime, and extend the lifecycle of your crushing equipment.

polab® laboratory automation

polab® laboratory automation offers a complete portfolio ranging from manual sampling stations to fully automated pneumatic sample transport, from semiautomatic sample preparation to custom-build, fully autonomous robotic laboratory automation solutions. polab® laboratory automation systems have been operating in industrial plants around the globe for more than 50 years – and our in-house R&D, Software and Process Teams ensure that innovative, high-ROI solutions for all applications are available.

Unplanned downtime in production monitoring can lead to significant losses. That’s why regular inspection and servicing of your polab® system is essential. At thyssenkrupp Polysius, we offer tailored maintenance solutions conducted by our specialists at agreed intervals—ensuring your laboratory automation system remains reliable and cost-effective.

Our services include comprehensive system checks, replacement of wear-sensitive components, rapid spare parts supply, and integration of the latest technological advancements. With customized spare parts packages and expert support, we help you maintain operational continuity and extend the lifecycle of your polab® installation—regardless of the automation system in place

Tube mills

The proven classical option for grinding. The mill is a robust and reliable solution. The mill can be installed in combination with a polycom®. thyssenkrupp Polysius offers this mills also as a dry mill in combination with a separator circuit.

thyssenkrupp Polysius offers comprehensive service solutions and high-quality spare and wear parts for tube mills, ensuring long-term reliability and operational efficiency. With decades of experience and a deep understanding of grinding technology, our services cover everything from routine inspections and troubleshooting to full-scale retrofits and technical audits. Field and workshop services are conducted by trained specialists and include mechanical inspections, vibration analysis, lubrication system checks, and wear condition assessments.

Our goal is to identify potential issues early, reduce maintenance costs, and extend the service life of your equipment.

HPGR / polycom®

polycom® high-pressure grinding rolls (HPGR) from thyssenkrupp Polysius bring energy-efficient, low-wear comminution to hard-rock mining – cutting power and wear-part costs while delivering dependable performance across copper, gold, iron ore, platinum and more.

Engineered for concentrators, polycom® handles dry or moist feed from ~1–75 mm with high throughput and a compact footprint that fits easily into new builds or plant upgrades. The HPGR product contains more fines and beneficial microcracks, improving downstream grinding and boosting heap-leach recovery; as a primary stage ahead of ball mills it can raise plant capacity and reduce total grinding energy, while rugged roll surfaces ensure long service lives.

Kilns and Drums

Kilns and drums from thyssenkrupp ensure high operating reliability with minimal maintenance and inspection needs. Designed for durability and efficiency, they help reduce operating costs while maintaining continuous, trouble-free performance in demanding industrial processes.

With rotary kilns and drums in operation for several decades, ongoing maintenance and modernization are essential to ensure long-term performance and reliability. thyssenkrupp Polysius, with over 160 years of engineering and service expertise, offers tailored solutions designed to meet the specific requirements of your equipment.

Our modernization services cover everything from targeted spare and wear part assemblies to complex retrofit projects. Each measure is developed with technical precision to enhance operational efficiency and extend the service life of your rotary kilns and drums.

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Tobias Klegraf

Tobias Klegraf

Nils Hörster

Nils Hörster