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The Benefits of High-Performance Protective Coatings Systems in Mineral Processing

The Benefits of High-Performance Protective Coatings Systems in Mineral Processing
High performance protective coating systems in mineral processing applications provide an effective way of increasing safety, reducing repair time (MTTR), extending equipment lifecycle and improving reliability (MTBF). Up Faster, Run Longer, Down Less.

The performance and operational benefits of protective coating systems is maximised when products are specified appropriately for the equipment application, and the job to be done. In supporting mining industry stakeholders to combat against productivity and operational losses, we bring attention to 4 primary mechanisms of wear being Impact, Abrasion, Erosion and Corrosion as being the most impactful in terms of wear degradation effecting equipment reliability in the mineral processing environment.


As we move through 2025 well be publishing a series of articles providing more descriptions, information and recommendations for solutions to protect against these 4 mechanisms of wear. With that in mind, the detail below provides some insight into the benefits of properly specified protective coating solutions.


Here are the primary benefits:


Increased Equipment Lifespan - Mining equipment is exposed to abrasive materials such as ore, rock, and slurry, which cause wear and tear. The application of protective coatings extends the operational life of equipment like chutes, hoppers and mills, reducing instances of unplanned breakdowns while providing increased uptime supporting reliability and alignment with planned shutdown cycles.


Improved Operational Efficiency – Equipment degradation due to wear leads to inefficiencies, reduced processing speed or breakdown, clogging or reduced throughput. Protection coatings ensure smoother operations, maintaining optimal performance and reducing energy consumption. 

 

Minimized Downtime - Unplanned shutdowns due to wear-related failures are costly in terms of repair but more importantly in terms of lost productivity and production output. The use of properly specified protective coatings and abrasion-resistant materials reduces the risk of unexpected breakdowns, ensuring consistent production schedules. 

 

Cost Savings - Investing in the use of protective coatings reduces the total cost of ownership (TCO) by lowering the frequency of part replacements and labor costs associated with repairs and prevents costly production stoppages caused by equipment failure. 

 

Enhanced Safety – The effects of impact, abrasion, erosion and corrosion can cause structural weaknesses in equipment, posing safety risks. Proper protection helps maintain the integrity of equipment, ensuring safer working conditions. 

 

Optimized Product Quality – Wear can cause contamination of processed materials with metal particles from worn equipment. Protection ensures a cleaner process, maintaining the quality of the mined product. 

 

Sustainability - Prolonging equipment lifecycle conserves resources while reducing the waste generated from frequent replacements to minimize the environmental impact of mining operations.


Look out for our next article providing more insight into the 4 Mechanisms of Wear, followed by subsequent articles describing the wear types and while providing solutions on how to maximise plant availability through correct protective coatings specification.


For more detailed information, advice and specification regarding protective coating solutions supporting mining and mineral processing productivity, please contact Mark Humphry, ITW’s Specification Manager, to learn more: +61 409 148 837 or mark.humphry@itwpf.com

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