Tasman Warajay

Materials Handling Optimisation - Since 1994

Materials Handling Optimisation (MHO)

Site Expansion and Improvements

Site Expansion and Improvements

Similar Projects

Product Handling - Potash


Phase 1: (4) Transfer Points
Phase 2: (3) Transfer Points


  • Lower dust and spillage levels
  • Simplify maintenance and cleanout
  • Increase yearly site throughput

Transfer Detail

Multiple transfer points were upgraded in two phases. Conveyor belt widths included 152.5cm and 183cm belts. Total height varied between 5.8m. and 18.3. Most transfer towers were 1-on-2 transfer points, but additionally there were 1-on-1 transfer points.


During the first phase of the project, there were four existing transfer points that were targeted for full replacement of both tower steel and transfer components. The second phase of the project included expanding one transfer from phase one and adding two entirely new transfer towers with the goal of increasing yearly site throughput.
The main maintenance objectives included keeping dust and spillage levels low, and providing easy access for maintenance and cleanout. The white and red potash being run by the facility would degrade and generate significant amounts of dust if not handled through the transfer point properly.
In terms of maintenance access, the operations team washes down the outside and inside of the transfer point between running different grades of potash, so being able to access all crevasses in the new solution was critical.

Tasman Warajay Solution

Tasman Warajay FlowFirst™ design was provided for all of the transfer points. Component geometry was highly engineered with Tasman Warajay® Technology to keep impacts low and softly center-load the receiving conveyor belts. Material flowed through the towers gently, keeping degradation to a minimum. Construction of the steelwork sections included airtight access doors and externally removable flow plates for easy liner replacement.
As part of the second phase goal of increasing throughput, the FlowFirst™ transfers were designed to handle a facility’s operational tonnages with minimal downtime.
Finally, Tasman Warajay cleaners were installed on all of the towers to properly clean the feed conveyor belts, which aids in reducing carryback and decreases dust.


By partnering with Tasman Warajay, the facility has been able to keep dust generation to negligible levels. Access for cleanout and maintenance has been sufficient to ensure material purity when switching between grades.
The current plan is to complete installation of the second phase transfers some time in 2017. When it is complete, the facility and the engineers are both confident that the new transfer points will allow the site to achieve its increased yearly throughput target.

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