CHALLENGES

At a large iron ore mining operation processing abrasive magnetite ore, the vibrating feeder floors were originally lined with hardened steel plates. Due to high impact and continuous high-volume ore flow from the chute above, these steel liners experienced rapid wear.

With four feeders in active operation and a fifth maintained as a rotatable spare, the site was required to replace feeder liners during every scheduled maintenance shutdown. This frequent intervention increased downtime, maintenance costs, and operational risk.

Key challenges included:
• Rapid wear of hardened steel liners under high-impact, abrasive conditions.
• Frequent liner change-outs during planned shutdowns.
• Reduced feeder availability impacting production efficiency.
• The need for a long-life, low-maintenance lining solution.
• Improving overall feeder reliability across the site.

SOLUTION

To address these challenges, steel backed Cera-Wear Extreme Ceramic Liners manufactured by Forech were supplied through our trusted channel partner Reglin Rubber (Australia).

The ceramic liners feature 92% alumina ceramic tiles fully vulcanised into a tough rubber matrix, backed with mild steel for secure mechanical fastening. The rubber layer beneath and between the ceramic tiles provides shock absorption, allowing the liners to manage impact energy while the ceramic surface delivers superior abrasion resistance compared to hardened steel.

The liners were supplied pre-cut with welded studs and ready for installation, designed to match the feeder floor layout. Installation was first completed in the spare feeder, which was then rotated into service to minimise operational disruption.

OUTCOME

Once operational, the upgraded ceramic-lined feeder delivered the following results:
• Wear life improved by approximately 5–6 times compared to previous steel liners.
• Significant reduction in liner replacement frequency.
• Lower long-term maintenance costs.
• Improved feeder availability and reduced shutdown intervention.
• Proven performance under identical operating conditions.

The success of the initial installation led to all feeders on site being upgraded with the same ceramic liner solution.

CONCLUSION

By switching to Forech-manufactured Cera-Wear Extreme Ceramic Liners, supplied via Reglin Rubber (Australia), the iron ore mine significantly extended feeder life and reduced maintenance demands. This case study demonstrates how engineered ceramic wear solutions can dramatically improve equipment reliability in high-impact, abrasive mining applications.