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Switchgear integrated into the mini substation forms a key component of the fully assembled power distribution solution supplied by Trafo Power Solutions. (Image source: Trafo Power Solutions)

Energy

As mining operations expand, deepen and adapt to shifting production demands, the need for flexible and scalable electrical infrastructure is becoming increasingly critical

According to David Claassen, managing director of Trafo Power Solutions, designing systems that can evolve alongside a mine’s lifecycle helps operators avoid expensive redesigns while maintaining operational continuity.

“Mining is dynamic by nature, and this fundamentally shapes our approach to designing transformers, modular substations and other solutions for the sector,” explained David Claassen, managing director of Trafo Power Solution. “Mines often need to move equipment around, for instance, and even the load requirements may change over time - so we design with that in mind.”

For Trafo Power Solutions, this means engaging with customers at the earliest possible stage of project development. In many cases, involvement begins before formal feasibility studies are completed. During concept or desktop study phases, mining houses typically require high level budget estimates, and this is where the company starts contributing to long term electrical planning.

“We get involved at pre-feasibility or even concept stage,” commented Claassen.

“Our tender and proposals department is geared to provide indicative costing very quickly - using our wide reference base where we have detailed data on our extensive installed footprint.”

Early collaboration allows the company to influence key technical decisions before they are locked in. By participating in discussions around transformer capacity, substation configuration and overall layout, Trafo Power Solutions helps ensure that infrastructure decisions reflect not only immediate power requirements but also the full life of mine strategy.

“By talking to customers early and asking the right questions, we develop an understanding of what their future plans are and can design accordingly. Instead of providing a 2 MVA transformer, we might suggest a 3 MVA unit that fits the same footprint, to avoid the cost and operational disruption of upgrading,” remarked Claassen.

Designing for future growth also supports better cost management at start up. Mines are increasingly opting for containerised modular substations because of their inherent mobility and scalability, as well as their reduced need for extensive civil works. Unlike conventional brick and mortar installations, modular substations can be relocated as mining activities shift, enabling phased developments and changing production priorities.

“Modular substations lend themselves to flexibility because of their plug-and-play design,” said Claassen. “Our skid-mounted or mobile options are ideal for mining operations where relocation is expected, whether underground or on surface.”

By prioritising adaptability over fixed, once off solutions, Trafo Power Solutions ensures that electrical systems remain aligned with operational realities over the long term. Mines are therefore better positioned to increase output, adjust layouts or accelerate expansion without being restricted by infrastructure designed solely for initial conditions.

“Our aim is to give our clients the best possible experience at all levels - and at every stage in the life of their project,” he concluded. “We take responsibility, we ask the right questions and we make sure the infrastructure we supply keeps supporting them long into the future.”

Cat expands diesel power options for construction machinery. (Image source: Caterpillar)

Construction

Caterpillar is introducing a new twin-turbo, 173-horsepower (129 kW) option for the Cat C3.6 diesel engine engineered for small- to medium-sized construction equipment
 
Announced at the CONEXPO-CON/AGG 2026 event this week, it offers a 21% increase in power over Caterpillar’s current lineup of 3.6-litre engines meeting US EPA Tier 4 Final/EU Stage V emission standards.
 
The 173-hp C3.6 achieves the higher power rating through an upgraded combustion system and reinforced core components, improving machine performance through higher torque, greater uptime, and lower total operating costs without increasing size or complexity.
 
Also at the event, the company will showcase the 74 hp Cat C2.2 engine, the power-dense 690 hp C13D engine under development, the 800 hp C18 series-turbocharged engine, and a remanufactured C7 highlighting the advantages of restoring old components to like-new performance.
 
“As the construction landscape changes, our extensive portfolio of solutions and expertise, from full-fleet jobsites through to a full range of optimised diesel engines, will help solve our customers toughest challenges,” said Steve Ferguson, senior vice-president of Caterpillar Industrial Power Systems.
 
CONEXPO-CON/AGG 2026 marks the first showing of the new up to 173 hp (129 kW) high horsepower diesel engine, the latest addition to the C3.6 range, which also includes 74 hp (55 kW) and 142 hp (106 kW) ratings.
 
To meet customers’ ongoing needs for higher power density power systems, which boost machine capability without increasing size or complexity, the twin-turbo C3.6 has been designed to deliver higher torque, greater uptime, and lower total operating costs for a range of equipment including wheel excavators, dumper trucks, soil compactors, backhoe loaders, asphalt pavers and telehandlers.
 
To achieve up to 173 hp (129 kW) and 546 lb ft (740 Nm) at 1500 rpm of power density from the proven 3.6 litre, four-cylinder platform, engineers have upgraded the combustion system to achieve maximum power and efficiency and have strengthened many core components.
 
The new offering offers end users up to 1000-hour oil and fuel filter intervals and gives customers greater fuel flexibility, as the engine is compatible with B20 biodiesel, 100% HVO (hydrotreated vegetable oil), and other sustainable fuels.
 
The high horsepower variant has been designed for low fluid consumption while delivering the required power across high, medium and low load operations.
 
With a transparent, maintenance free after-treatment system with no downtime, the engine is set to deliver serious power in a compact footprint for a wide range of OEMs whose equipment is the bedrock of construction sites around the world, according to Ferguson.
 
“The customer requirement for high power density to boost machine capability without increasing engine size or complexity has driven the launch of this new high horsepower C3.6 and the C13D which we unveiled at CONEXPO-CON/AGG 2023,” he said.
 
“Given that internal combustion engines remain the dominant power solution across global jobsites; we continue to strategically invest in advanced diesel engine technologies that help customers tackle their daily challenges.”
 
The Caterpillar booth features the C13D diesel engine platform, designed to achieve best-in-class power density, torque and fuel efficiency for optimising the performance of heavy duty off-highway applications, including rock crushers, screeners, and grinders; trenchers; agriculture tractors, harvesters and self-propelled sprayers; woodchippers; material-handling equipment; and large industrial pumps.
 
For customers considering a range of power solutions for their equipment, the booth also features a C9.3B fitted with a diesel-electric power unit.
 
Read more:
 
 
 
 
 
 
 

The rebuilt Sandvik hydraulic hammer is ready for installation at site. (Image source: Sandvik Rock Processing)

Mining

Sandvik Rock Processing has finalised a comprehensive OEM-level refurbishment of a Sandvik BR3288i hydraulic breaker and a Sandvik BB8094R breaker boom for a leading gold mining operation in Ghana

The project restored a key component of the site’s primary crushing circuit, with the rebuild, reinstallation and commissioning delivering measurable gains in equipment availability and output. Ongoing quarterly inspections and technical support from the company’s Kumasi-based team continue to reinforce performance.

The refurbishment was carried out at Sandvik Rock Processing’s fully equipped workshop in Kumasi. The breaker and boom assembly are installed at the mine’s run-of-mine grizzly, where oversized rocks generated during blasting are reduced to prevent blockages and maintain smooth material flow into the crusher.

“This project restored a vital asset that plays a central role in the mine’s primary crushing circuit,” commented Amos Fordjour, senior service technician at Sandvik Rock Processing. “Our extensive rebuild has returned the machine to OEM performance standards, significantly improving the mine’s reliability and production continuity.”

After more than five years in operation, the equipment was scheduled for refurbishment. Work commenced on site, where the 11 tonne boom assembly was dismantled using the mine’s crane infrastructure before being transported over a three-hour journey to the Kumasi workshop.

“Once in the workshop, our technicians stripped the units completely - checking for critical components such as pins, bushings, cylinder seals and mounting brackets that required replacement,” remarked Fordjour. “The boom was sandblasted and inspected for cracks, the hydraulic cylinders were rebuilt and pressure-tested and the hammer was fully refurbished.”

Haqq Abdul Rahman, graduate technician at Sandvik Rock Processing, highlighted the importance of parts availability in reducing turnaround times. He explained that mines frequently face challenges with oversized rocks at the run-of-mine grizzly, and temporary mobile breakers often require considerably more time to handle the material.

“It was important that we controlled the turnaround time on this project so the mine could put the equipment back to work as soon as possible,” said Rahman. “This particular unit breaks oversized rocks much faster than the smaller mobile units that the mine had to rely on while this one was being refurbished.”

The Sandvik BB8094R breaker boom, rated at 55 kW input power, provides a maximum reach of 12.7 m, with nominal horizontal and vertical reaches of 9.8 m and 9 m respectively, and a full 360° swing capability. The 2.3 tonne Sandvik BR3288i hydraulic breaker incorporates an operating principle that optimises stroke length, blow energy and includes an idle blow protector, enabling adaptability across applications while enhancing hydraulic efficiency and operational safety.

Fordjour underscored the role of strict quality control procedures throughout the refurbishment.

“We follow strict operating procedures and standards in everything we do,” continued Rahman. “This includes using only genuine Sandvik parts which allows us to guarantee the quality of both the components and the workmanship.”

Following workshop completion, Sandvik Rock Processing teams returned to site for installation and commissioning. The three-week process required detailed coordination around crane usage, electrical integration, positioning and safety compliance.

“We work very closely with customers during removal, installation and commissioning,” Fordjour noted. “In this case, the mine provided the cranes and support equipment and we handled all the technical work; that collaboration is critical.”

Rahman explained that the restored boom and breaker now offer enhanced structural integrity, precise OEM clearances and improved swing performance, supporting efficient energy transfer and high twist resistance under demanding impact conditions.

“For the mine, the biggest impact is uptime and production,” said Rahman. “Without this breaker, their crushing circuit slows down considerably; now that it is back to full performance and production is consistent again.”

Post-commissioning support remains ongoing, with Sandvik Rock Processing conducting quarterly inspections to assess pins, seals and overall structural condition, while maintaining readiness for service interventions whenever required.

AD Ports Group and two UAE based investors will hold a combined 60% stake in the operating company, alongside Africa Ports Development LTD with 40%. (Image source: AD Ports Group)

Logistics

AD Ports Group has entered Africa Ports Development’s 30 year concession to develop and operate a new dry bulk terminal at the Port of Douala in the Republic of Cameroon, marking a further expansion of its African footprint

Under the agreed investment framework, AD Ports Group and two UAE based investors will hold a combined 60% stake in the operating company, alongside Africa Ports Development LTD with 40%. This structure translates into an effective economic interest of 51% for AD Ports Group.

Aligned with its ownership share, AD Ports Group’s portion of the phase 1 investment is projected at approximately AED 320 million, (approx. US$87mn). The first phase will deliver two berths and roughly 450 metres of quay wall, with an annual handling capacity of about 4 million tonnes of dry bulk commodities including clinker, gypsum, fertiliser and grain.

Construction is scheduled between 2026 and 2028 and will be undertaken in close coordination with the Port Authority of Douala to respond to sustained demand at Cameroon’s main maritime gateway.

Mohamed Eidha Al Menhali, Regional CEO - AD Ports Group, said, “This agreement represents a strategically important expansion of AD Ports Group’s presence in Africa and reinforces our commitment to developing high-impact maritime infrastructure in high-growth markets, in line with the vision of our wise leadership. The Douala dry bulk terminal will enhance trade resilience, support industrial development, and strengthen Cameroon’s role as a gateway to Central Africa.”

Al Menhali added: “Through our partnership with Africa Ports Development, we are combining local market expertise with AD Ports Group’s global capabilities in port development and operations to support the Port Authority of Douala’s plans to modernise and enhance Douala Port, enabling regional trade and long-term economic growth. We commend the Port Authority for the significant progress achieved in recent years, which has driven strong growth in Cameroon’s maritime sector, and we look forward to contributing further to its long-term development ambitions.”

Marc Tabchy, managing partner of Africa Ports Development, said,“We are honoured to bring this partnership to life with AD Ports Group, a global reference that shares our firm belief in this project, in Cameroon, and in the potential of the African continent. Building upon the opportunity provided by the Port Authority of Douala’s modernisation and specialisation initiatives, this collaboration establishes a strategic synergy combining our group’s ambition and regional depth with AD Ports Group’s operational excellence.”

Situated at the Port of Douala, Cameroon’s largest seaport and the primary entry point for bulk imports, the new terminal is expected to reinforce regional supply chains and improve the handling efficiency of essential cargo streams. The port also functions as a vital transit corridor for landlocked markets across Central Africa, and the project will benefit from established hinterland connections linking Douala to major industrial zones and regional trade routes.

The development forms part of AD Ports Group’s broader growth strategy across the continent, building on its existing operations and investments in Egypt, Morocco, Tunisia, Kenya, Tanzania, Angola and the Republic of the Congo, and strengthening its role as a key partner for trade, logistics and enabling infrastructure in Africa.

 
 

Revitalising Nigeria’s power industry. (Image source: AFC)

Finance

Africa Finance Corporation (AFC) confirmed its advisory role in a recent landmark bond issue that aims to resolve many of the deep-rooted problems that have long blighted Nigeria’s power sector

The Nigeria’s government recently issued N501bn (US$358mn) as the inaugural tranche of the N4 trillion (US$2.9bn) power sector bond programme under the Presidential Power Sector Financial Reforms Programme (PPSFRP).

The initiative is designed to resolve more than a decade of legacy debts that have constrained liquidity, discouraged investment and weakened confidence across the electricity value chain.

It forms an integral part of sweeping power sector reforms, marking a major step toward restoring financial stability in the electricity market.

The bond programme will be used to settle verified outstanding receivables owed to power generation companies for electricity supplied between February 2015 and March 2025.

By clearing arrears, the government aims to reset the financial foundation of the power market and strengthen the balance sheets of the generating firms.

“The successful issuance of the inaugural tranche under the power sector bond programme underscores AFC’s commitment to supporting transformative reforms in Nigeria’s power sector,” said Banji Fehintola, executive board member and head, financial services at AFC.

“By resolving long-standing liquidity challenges and restoring confidence among investors and operators, this transaction lays the foundation for sustainable growth and improved electricity supply across the country.”

AFC acted as co-financial adviser, providing support on programme design, negotiation strategy, settlement agreements with the generating companies and the structuring of the bond issuance.

The transaction mobilised significant domestic capital, with pension fund administrators accounting for roughly half of the total financing, highlighting growing local investor confidence in the reform agenda.

Officials say the programme goes beyond debt resolution and forms part of a broader package of power sector reforms that includes investments in transmission infrastructure, accelerated rollout of consumer metering and a transition toward bilateral electricity trading based on market-reflective pricing.

Together, the measures are intended to create a more transparent, commercially viable and sustainable electricity market.

When fully implemented, the programme is expected to impact about 5,398MW of generation capacity and settle payments for more than 290,000GWh of electricity supplied over the past decade, benefiting companies serving around 12 million registered customers nationwide.

The bond programme is major step toward reviving Nigeria’s electricity sector, according to Olu Verheijen, Special Advisor to the President on Energy.

“The programme represents a decisive reset of Nigeria’s electricity market, combining debt resolution with broader financial and structural reforms,” said Verheijen.

“AFC brought strong sector expertise, deep local market knowledge and a clear understanding of the market’s commercial complexities, playing a critical role in delivering a credible outcome that supports liquidity restoration, investor confidence and long-term sustainability.”

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Modular design is the key to streamline product portfolios

Manufacturing

A new report from management consultancy Arthur D. Little warns that rising product portfolio complexity is quietly eroding profitability in the manufacturing sector, constraining digital growth, and limiting operational flexibility.

The study, Rise of Complexity in Manufacturing, highlights that companies must take decisive action to simplify their offerings and leverage modularisation to stay competitive.

“Unchecked complexity is a silent profitability killer,” the report states. “With resources limited and markets increasingly commoditised, companies must reduce product portfolio complexity to drive profitability and innovation.”

Manufacturers often expand product variants to meet customer demand, but without systematic portfolio pruning, these efforts generate hidden costs. Non-customer-facing complexity such as outdated products, excessive SKUs, and intricate internal processes can slow development, reduce scalability, and impede time to market.

The report identifies four key challenges for manufacturers: maintaining profitability amid market commoditisation, differentiating through digital solutions, ensuring supply chain resilience, and balancing legacy systems with emerging technologies such as new materials, battery-powered engines, or alternative fuels.

Arthur D. Little recommends a data-driven approach to complexity, starting with measuring the cost of complexity (CoC) across product lines and functions. A monetary proxy for CoC can capture inefficiencies in development, manufacturing, warehousing, and support, helping firms identify underperforming products for phaseout.

Strategic modularisation is highlighted as a crucial tool for managing complexity. By designing standardised, interchangeable product modules, manufacturers can simplify portfolios, accelerate time to market, and reduce costs while enabling cost-effective customisation.

The report cites Electrolux, which cut component numbers by 40% and reduced development time by 30% through modular design, and Siemens, which applied modularity to its industrial automation systems, reducing design time by 40% and improving scalability.

Arthur D. Little stresses that complexity reduction requires more than technical solutions: it demands cross-functional coordination, strong governance, and a cultural shift away from short-term gains. Companies must embed modular principles in product development, eliminate low-performing products, and ensure that both hardware and software systems are designed with simplicity in mind.

“Reducing product portfolio complexity is not a technical fix — it is a strategic transformation,” the report concludes. “By making complexity measurable, pruning underperforming products, and embedding modular design, manufacturers can release trapped value, improve speed to market, and build more resilient operations.”

The consultancy urges manufacturers to act decisively now, turning awareness of complexity into structured strategies for long-term profitability and innovation.