Reducing unplanned downtime remains one of the most pressing challenges facing mining operations, with direct implications for productivity, operating costs and equipment longevity. This was a central theme during a recent webinar hosted by Creamer Media Webinars on behalf of global filtration technology provider Donaldson Filtration, where industry experts unpacked practical approaches to improving reliability through effective filtration and maintenance practices.

Opening the session, Donaldson Filtration industrial sales director Brian Gabriel highlighted the importance of aligning filtration strategies with broader operational goals. He noted that mining remains a critical growth sector for the company, with tailored, holistic solutions aimed at enabling operators to focus on production while maintaining safe and efficient environments.

A key message from the webinar was that relatively low-cost components – such as filters, seals and lubricants – play a disproportionately large role in protecting high-value equipment. Donaldson sales manager Reuben Phasha explained that mining equipment components can broadly be categorised into three levels: long-life structural parts, midlife mechanical components and wear parts. While wear parts are inexpensive and routinely replaced, their failure can trigger damage to far more costly systems.

“The level three components exist purely to protect the level one and level two components,” Phasha noted, warning that neglecting these basic elements can lead to premature failure, increased operating costs and unplanned downtime.

Contamination – particularly dust – remains one of the most significant contributors to equipment failure in mining environments. According to Phasha, between 75% and 80% of hydraulic and pneumatic system failures are linked to contamination, while more than 70% of manufacturing losses can be traced to human error. These findings underscore the importance of disciplined maintenance practices and early detection of performance deviations.

Common early warning signs, such as abnormal fuel consumption, pressure drops, overheating and excessive engine smoke, are often overlooked, despite providing critical insights into developing faults. Failure to act on these indicators can result in catastrophic breakdowns and costly production interruptions.

From a regional perspective, superior filtration systems provider and sole Donaldson filter distributor Filtros & Tubos Mozambique GM Glenn Stoffberg provided insight into operational challenges in emerging mining markets. He emphasised the importance of reliability and stock availability in regions where supply chain constraints, such as foreign exchange shortages, can delay the delivery of critical components.

Despite these challenges, Stoffberg noted that consistent product performance and strong technical support have enabled long-term customer relationships. In many cases, filtration solutions have demonstrated clear benefits in reducing downtime and improving operational efficiency, allowing suppliers to displace original equipment manufacturer products.

On the industrial side, Donaldson head of industrial air filtration for Africa Atish Singh stressed that dust control should not be viewed solely as a compliance requirement. Instead, it represents a significant opportunity to enhance plant performance and reduce downtime.

“Effectively controlled dust extraction can prevent premature equipment wear, system blockages, overheating and unexpected shutdowns,” Singh explained.

Dust-related failures typically occur through predictable mechanisms, including abrasive wear on components, clogging of filters and ducts, overheating of motors and instrumentation failures. These issues can disrupt production flows, particularly in high-impact areas such as crushing plants, conveyor systems and processing facilities.

Singh advocated for a proactive approach that focuses on capturing dust at the source, supported by appropriate filter media and automated cleaning systems. This strategy, combined with regular maintenance and service-level agreements, can significantly improve system reliability.

A practical example of these principles in action was presented by DV Projects & Maintenance MD Dirk Visagie, who detailed a dust extraction upgrade at a platinum mine. The project involved replacing outdated filtration systems with more compact, high-efficiency units, resulting in substantial performance improvements.

The new system reduced maintenance downtime for filter changes from a full day to just 30 minutes, while also lowering yearly maintenance costs by more than 70%. In addition, energy savings were achieved through improved airflow efficiency, demonstrating the broader operational benefits of advanced filtration technologies.

Panellists also highlighted the growing role of digital monitoring tools in supporting predictive maintenance. Systems capable of tracking variables such as differential pressure and filter loading can provide real-time insights, enabling operators to address issues before they escalate into failures.

Ultimately, the webinar reinforced that reducing downtime in mining is not reliant on a single intervention, but rather on a combination of disciplined maintenance, effective contamination control and the strategic use of technology.

As Gabriel concluded, understanding the “hidden costs” associated with poor filtration and maintenance practices is essential. By focusing on total cost of ownership rather than upfront savings, mining operations can unlock significant value through improved reliability, extended equipment life and sustained production performance.