Mines and quarries across Africa are pushing to maximise output from existing infrastructure while keeping capital expenditure under tight control – and Sandvik Rock Processing’s Reborn programme does just this for ageing crushing equipment.

“Our Reborn programme is more than a refurbishment,” says PC Kruger, Business Line Manager Crushing at Sandvik Rock Processing. “Rather, it is a strategic lifecycle solution that enables customers to renew critical crushing assets while improving reliability, incorporating newer technology and extending operational life.”

This approach has become increasingly relevant in Africa, Kruger points out, where many crushing circuits installed during earlier mining and quarrying expansions are now reaching maturity. He highlights that a crusher is not an equipment item that customers replace every few years.

“If it was installed two decades ago and is still at the heart of the process plant, the question becomes: how do you restore performance and reliability without rebuilding the whole operation around it?” he explains.

The Reborn programme answers this question by replacing the crusher itself – fully assembled and factory tested – while retaining supporting infrastructure such as motors, lubrication systems, filters and structural steelwork wherever practical.

“The footprint remains the same, so the replacement crusher fits directly into the existing plant layout,” Kruger says. “That means customers can remove their old unit during a planned shutdown and install the Reborn crusher in its place with minimal disruption. It becomes a plug-and-play replacement with the benefit of modern technology.”

This approach carries significant advantages over a traditional site-based refurbishment. Transport logistics alone severely complicate the conventional process of refurbishment. Removing a crusher from a remote site, transporting it to a workshop, rebuilding it and returning it to operation can create extended downtime and substantial cost – especially in regions where access to specialised engineering infrastructure is limited.

“In many parts of Africa, the logistics are incredibly challenging and costly, especially when moving heavy equipment across borders to a workshop and back again,” Kruger says. “With Reborn, the customer gets a factory-approved replacement installed quickly, while avoiding the downtime and risk associated with stripping and rebuilding an ageing machine in the field.”

Installing a Reborn crusher also ensures that OEM tolerances, materials and testing are observed. He notes that when crushers are repaired component by component over many years wear accumulates and parts often do not mesh the way they should.

“With Reborn, customers receive a crusher built to original specifications, tested in the factory and backed by Sandvik Rock Processing,” he says. “That gives them confidence in reliability and performance from day one.”

Benita Gajoo, Sandvik Rock Processing’s Aftermarket Lead for Africa, highlights that Reborn crushers incorporate the latest upgrades such as redesigned internal components, improved wear performance, updated mechanical assemblies and refinements that make servicing easier and safer.

“These upgrades also help to support customers’ growing priorities around sustainability and resource efficiency,” Gajoo says. “Beyond throughput and economy, customers are increasingly focused on efficiency, energy use and environmental performance. Reborn supports that by upgrading critical equipment without replacing everything around it.”

This allows the mine to avoid scrapping its entire crusher installation and to instead retain components with service life.

“That is a more sustainable use of resources and a smarter long term approach to plant management,” she says.

The widely varying conditions across Africa mean that Sandvik Rock Processing treats each Reborn project as site-specific. Existing infrastructure is assessed, ancillary systems are inspected and recommendations are made based on plant condition, duty cycle and customer production targets.

“We are happy to go to site for inspections and discussions, to help the customer decide what makes sense,” Kruger says. “In some cases, most of the existing auxiliary equipment can be retained while in others, it may be worthwhile to conduct additional upgrades. It is about finding the best technical and economic fit for that operation.”