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ECORA Solutions

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ECORA Solutions

ECORA Solutions helps Australian mines reduce carryback, build-up material and downtime.

We improve material flow and equipment performance on haul trucks, excavators, crushers, chutes, conveyors and rail wagons with eco-friendly surface technology.

20/10/2026

A Trial Is Only Useful If It Is Measured.

Every ECORA trial begins by establishing an operational baseline, because a change you cannot quantify is a change you cannot justify. The metrics are selected with the site according to the equipment, the commodity and the objectives — tonnes moved per shift, equipment availability, downtime caused by build-up, cleaning hours per month, equipment cycle time, throughput, payload efficiency, cost per tonne moved, safety interventions avoided, and return on investment with the associated payback period.

The comparison is then made on recorded site data rather than visual observation alone. At the end of the trial, ECORA provides a performance report comparing the baseline and treated periods, quantifying the benefit in operational, maintenance, safety and financial terms, and recommending the application system, consumable rate, maintenance approach and monitoring plan best suited to the operation. The objective is not to demonstrate that something looks cleaner. It is to show, in your own numbers, what changed.

19/10/2026

Coal Does Not Travel in a Straight Line.

Between the mine face and the vessel, coal passes through truck trays, feeders, crushers, transfer chutes, conveyors, hoppers, silos, stackers, reclaimers, train loading facilities and rail wagons. Every one of those transfers is a place where material can adhere, accumulate and restrict flow. Truck tray carryback, crusher feed hopper build-up, transfer chute blockages, belt carryback, bin hang-ups, stacker carryback, train load-out build-up, wagon carryback and ship loader chute build-up are all the same underlying problem appearing in a different piece of equipment.

Coal is one of the most difficult bulk materials to handle because of its variable moisture content, particle size distribution, clay contamination and the fines generated during crushing and handling. Those characteristics increase adhesion between the coal and the steel, particularly in wet or humid conditions. By reducing that adhesion at the surface, ECORA helps keep material moving through the transfer points that decide overall plant throughput.

15/10/2026

Preventive or Reactive?

Most operations already have a way of dealing with build-up. The question is whether that method prevents material from adhering, or restores flow after it has already accumulated.

Preventive controls reduce adhesion before build-up develops: low-friction and wear liners, design modifications that improve flow geometry, and ECORA, which reduces adhesion at the steel surface itself. Reactive controls restore flow once material is already there: air cannons that break bridging in chutes and hoppers, mechanical vi*****rs, water washing and sprays, and manual or mechanical cleaning after isolation. Conveyor belt cleaners sit in both categories.

ECORA is one of the few options that works on both sides. It reduces initial adhesion and, following application and operation, assists in releasing build-up that has already formed — and it works independently or alongside the controls already installed on site.

14/10/2026

Dry Conditions Do Not Mean Clean Equipment.

Material build-up is often assumed to be a wet-season problem. It is not. These images were taken through a single shift in the Western Australian Goldfields, in dry, high-temperature conditions, and they show carryback progressively anchoring to the tray of an untreated CAT 777 between 07:44 and 10:38.

Even in dry climates, moisture reaches the material through ore geology, groundwater, dust suppression systems, processing activities, rainfall events and stockpile management. When that moisture meets fines, clay content and the natural roughness of a steel tray, the first layer adheres — and once it does, further material compacts on top of it.

Fines plus residual moisture plus clay content plus surface roughness plus compaction equals build-up and carryback. The consequences follow the same pattern everywhere: reduced effective payload, restricted chute and hopper cross-section, higher cleaning demand and water consumption, and lower equipment availability.

13/10/2026

46% Lower Cost Per BCM.

Carryback is usually discussed as a cleaning problem. Measured properly, it is a cost-per-unit-volume problem. In a seven-day controlled trial on a Western Australian overburden operation running a fleet of 10 CAT 777 trucks, ECORA was applied daily to two haul trucks and to the hydraulic excavators, while baseline and treated performance were recorded side by side.

The measured outcome was an estimated 46% reduction in total operational cost per BCM. That figure comes from three compounding effects: bucket passes falling from 13 to between 6 and 8, trips per shift rising from 35 to 40 up to 45 to 52, and cleaning downtime of 30 to 45 minutes per event being eliminated. Together they produced an increase of 50% to 60% in the volume of material moved each day, using the same fleet, the same routes and the same shift pattern.

The cost was not reduced by cutting anything. It was reduced by moving more with what was already on site.

12/10/2026

From 13 Buckets to 6.

Loading is often where the haul cycle is really decided. In this Western Australian operation, material adhesion inside the excavator bucket was blocking up to 50% of the effective working capacity, and approximately 13 bucket passes were required to fill a single CAT 777. Every additional pass extended loading time, reduced truck utilisation and slowed the entire cycle behind it.

After ECORA was applied to the bucket, the number of passes required fell to between 6 and 8, improving loading efficiency by approximately 50% to 100%. With both excavators treated, trucks moved from 35 to 40 loads per shift up to 45 or more, and travel cycle time improved because loading was faster. No excessive bucket build-up was observed while daily application continued.

Treating the loading tool does not only make the excavator cleaner. It changes how much the entire fleet can move in the same shift.

08/10/2026

Zero Carryback Across a Full Shift.

In a Western Australian gold operation, haul trucks working in overburden and waste rock were retaining an average of 10% carryback per load, with peaks of up to 50%. Despite the dry, high-temperature Goldfields conditions, the material held enough inherent moisture to adhere firmly to the tray. The result was reduced payload efficiency, repeated manual scraping and 30 to 45 minutes of downtime for every cleaning event.

During a controlled seven-day field trial on two CAT 777 trucks, ECORA was applied daily following the trial protocol. The treated trucks achieved 100% payload discharge on every cycle and zero carryback across entire shifts of approximately 45 loads per day, with no cleaning required for the full trial period. Untreated sister trucks developed carryback from the first few loads, reached maximum build-up between the third and fifth load, and carried dead weight for 34 to 40 trips per shift.

07/10/2026

Engineered for the Chute. Designed for the Outcome.

Every ECORA chute solution is engineered around the equipment geometry, material characteristics, operating conditions and required performance outcome. Nozzle quantity, spray angle, nozzle selection and positioning are defined to reach critical adhesion zones without interfering with the intended material trajectory or restricting flow through the chute.

Installation design must also account for site safety, restricted access, maintainability and all relevant compliance requirements. By reducing build-up at these critical transfer points, ECORA can support more stable material flow, fewer blockages and less reliance on complex cleaning interventions. It can also help reduce damage associated with repeated scraping, impact cleaning and manual removal.

06/10/2026

Trial Readiness Starts with Safety and Competency.

A successful site trial begins well before the first application. It requires appropriately trained personnel, site-compliant PPE, task-specific controls and a clear understanding of the operating environment. Where work at heights or restricted access is involved, competencies, permits, exclusion zones and rescue requirements must be confirmed before the task begins.

ECORA trials are planned and executed to align with the safety, compliance and operational expectations of Tier 1 mining companies. Pre-start inspections, risk assessments and site procedures are integrated into the trial methodology so the work can be completed safely and without unnecessary disruption to operations. The objective is not only to demonstrate performance, but to do so with the same discipline expected for any critical site activity.

05/10/2026

When Cleaning Takes Two Production Assets Offline.

Removing compacted material from a truck tray with an excavator takes both assets out of productive service. The task requires a highly skilled operator to work with precision, as contact between the bucket and tray can damage the body, liners or structural surfaces. Even when performed carefully, repeated scraping can accelerate wear and increase maintenance demand.

The operational cost extends beyond the cleaning activity itself. Each intervention reduces equipment availability, interrupts the haul cycle and diverts an excavator from loading duties. By reducing material adhesion before heavy build-up develops, ECORA helps minimise the need for this type of cleaning and supports safer, more consistent use of the existing fleet.

Address

755 Hunter Street
Newcastle West
2302

Opening Hours

Monday	9am - 5pm
Tuesday	9am - 5pm
Wednesday	9am - 5pm
Thursday	9am - 5pm
Friday	9am - 5pm

Website

https://ecorasolutions.com/

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