How fuel system bottlenecks were slowing a Mpumalanga mining fleet.

In demanding mining environments, delays in machine commissioning can lead to production setbacks, increased costs, and operational inefficiencies. For a mining contractor operating in Mpumalanga, recurring downtime due to post-delivery fuel system installations created challenges that required immediate attention. Seeking to eliminate these delays and improve operational readiness, a solution was implemented that redefined their approach to fleet deployment.

Timely Deployment is Vital

Heavy-duty mining machines are critical assets that need to be fully operational upon arrival on site. Traditionally, machines were delivered without fuel systems installed, requiring third-party service providers to perform installations in the field. This created unnecessary standing time, increased coordination efforts, and pushed back production start times.

The impact of such delays is multifaceted. Not only do they reduce available working hours for each machine, but they also affect resource planning, team scheduling, and overall production targets. The need for a more proactive and seamless solution became evident.

A Forward-thinking Installation Strategy

To address these challenges, a new approach was adopted: pre-installing Wiggins fuel systems as a standard fitment during the machine build phase. This eliminated the need for site-based installations altogether.

Instead of coordinating with external suppliers post-delivery, the machines were now dispatched fully equipped with fuel systems, ready to enter production immediately. The installations were carried out at the build facility with consistent quality control and minimal operational disruption.

This strategic change meant that, upon delivery, the machines could be fuelled and mobilised without delay — ensuring that production schedules remained intact and asset productivity was maximised from day one.

Realised Benefits and Operational Gains

The shift to standardising Wiggins fuel system installations provided a number of immediate and long-term benefits:

• No Installation Delays: Machines were ready for use upon arrival, eliminating previous bottlenecks and planning disruptions.
• Faster Production Onboarding: Equipment could transition from delivery to active duty within hours, not days.
• Reduced Third-Party Dependencies: By removing the need for external fitment teams, the process became more controlled and predictable.
• Improved ROI: With less downtime and earlier machine activation, return on investment was accelerated significantly.

Supplied Over A Four-Month Period

This solution was implemented in Mpumalanga, South Africa over a period of four months — from April through July 2025 — covering multiple units that were commissioned for immediate deployment in a high-output mining environment.

FloSolve has been a trusted partner in delivering innovative solutions to the mining industry. Our Wiggins non-pressurised fuel system and flush face couplings are designed to enhance fuelling, efficiency, minimise fuel spillage, and improve safety on site. By ensuring clean, high-flow fuelling with minimal contamination, our system helps reduce equipment downtime, extend component life, and optimise overall fleet performance – leading to significant cost savings and increased operational reliability.