Revamps, Upgrades & Life Extension: OEM-Independent Solutions for Long-Term Equipment Performance
At MCI, we specialize in OEM-independent inspections, revamps, upgrades, refurbishments, repairs, and life enhancement programs for a wide range of continuous mining and material handling equipment. With expertise in stackers, reclaimers, ship loaders, conveyors, and bulk material handling systems, we provide custom-tailored solutions that ensure extended equipment lifespan, enhanced operational efficiency, and compliance with modern performance standards.
Full refurbished, modernized & relocated Bucket Wheel Excavator
OEM-Independent Inspections & Assessments
To accurately assess equipment conditions and identify potential performance improvements, we offer OEM-independent, unbiased inspections that cover:
- Initial Plant Audit & Status Assessment – Comprehensive visual inspections to detect structural wear, mechanical inefficiencies, and component degradation.
- Engineering Audit & Structural Analysis – Detailed assessment of load-bearing structures, mechanical components, and integrity risks.
- Machine Vibration & Heat Mapping Audit – Advanced diagnostics to identify misalignments, overheating, and potential mechanical failures.
- Control & Protective Device Testing & PLC Audits – Ensuring automation systems, PLCs, and safety protocols meet compliance standards.
- Welding Inspection with UT Testing – Ultrasonic testing (UT) for weld quality verification, ensuring long-term structural reliability.
- Alignment & Vibration Inspection – Laser alignment and dynamic vibration analysis to improve efficiency, reduce wear, and prevent failures.
Revamps, Upgrades, Modernization & Refurbishment Services
To meet evolving operational demands, we provide tailored revamp and modernization solutions that enhance efficiency, reliability, and capacity while ensuring compliance with modern performance and safety standards.
- Custom-Tailored Revamps & Retrofitting Solutions – Adapting legacy systems to meet new industry demands with minimal downtime.
- Capacity Extensions & Debottlenecking – Expanding system throughput while eliminating performance bottlenecks.
- Efficiency Enhancement Through Upgrades & Modernization – Implementing advanced automation, control systems, and optimized component designs.
- Reliability Improvement & Safety Upgrades – Upgrading protective systems, structural integrity, and fail-safe mechanisms.
- Execution of Complex Revamp & Outage Projects – Managing turnkey EPC revamp projects, including planning, execution, and commissioning.
- Custom-Tailored Risk & Profit Sharing Models – Offering flexible project execution models that align with financial and operational goals.
On Site Machining works & slew bearing changes
Life Enhancement, Predictive Maintenance & Engineering Optimization
To maximize the lifespan of mining and material handling equipment, MCI integrates predictive maintenance, performance optimization, and engineering-driven solutions into a comprehensive life cycle strategy.
- Predictive & Preventive Maintenance Strategies – Utilizing diagnostics, condition monitoring, and real-time analytics to detect potential failures before they occur.
- Sustainability & Energy Efficiency Improvements – Reducing energy consumption, dust emissions, and noise levels to enhance environmental compliance.
- Onsite Repairs & Component Overhauls – Conducting machining, welding, and reconditioning of major components to prevent premature failures and extend system life.
- Automation & Digitalization – Upgrading control systems, integrating IIoT solutions, and modernizing PLC logic for seamless operation.
- Feasibility & Environmental Impact Studies – Evaluating technical and economic viability of equipment upgrades and modernization projects.
- Detailed Engineering & Manufacturing of Individual Equipment – Designing and fabricating custom components to enhance system performance.
- Plant Optimization & Process Improvement – Identifying inefficiencies, improving throughput, and optimizing material flow.
- Operator Training & Knowledge Transfer – Ensuring on-site personnel are well-versed in new automation, safety protocols, and maintenance strategies.
Engineering FEM Analyses & Structual Audits
Equipment Relocation Services
At MCI, we specialize in the safe, efficient, and timely relocation of mining and material handling equipment. Our extensive experience ensures minimal downtime and maximized operational efficiency for your projects.
Our Equipment Relocation Services Include:
- Multi-wheel loader & transport crawler relocation: Expert handling of semi-mobile equipment.
- Heavy load road transport: Secure movement of oversized machinery.
- Partial disassembly & reassembly: Professional dismantling, transportation, and reassembly at the new site.
- Custom relocation planning: Tailored logistics to meet specific site requirements.
Why Choose MCI? Your Strategic Partner in Mining & Material Handling Equipment
With decades of experience in continuous mining, bulk material handling, and industrial automation, MCI provides cutting-edge solutions that ensure:
- Extended Equipment Life & Performance Enhancements – Through revamps, refurbishments, and preventive maintenance programs.
- Reduced Downtime & Operational Efficiency – Implementing advanced automation, predictive diagnostics, and reliability improvements.
- Compliance with Industry Standards & Sustainability – Reducing environmental footprint, energy costs, and maintenance expenses.
Contact us today to discuss how MCI can enhance your operations with expert inspection, revamp, and optimization solutions.
In line with our commitment to comprehensive service, we also focus on the following:
- Automation and Software Optimization: Implementing the latest in automation and software to streamline your operations.
- Complete Service Package: From environmental analysis to shutdown management, our range covers all aspects of mining equipment maintenance, optimization, and repair.
- Operator Training for Enhanced Efficiency: Ensuring your team is fully trained on the new technologies, systems, and repair techniques for maximum efficiency.
Our approach is holistic, encompassing every aspect of your mining and material handling systems:
Rigorous Ramp-Up and Performance Testing: We thoroughly test each system after refurbishment and repair to ensure peak performance.
Uncompromised Quality Management and Assurance: Our quality management system guarantees that every refurbishment, revamp, and repair meets the highest standards.
In addition to these services, we offer:
- Engineering Studies, Inspections, and Audits
- Environmental Analyses and Feasibility Studies
- Solutions for Debottlenecking and Plant Optimization
Selecting MCI for your mining machinery and material handling system requirements is a choice for unparalleled expertise in this specialized sector. We pride ourselves on being more than just a service provider; we are a partner who profoundly understands the complexities, demands, and needs of the mining industry. Our goal at MCI is not merely to refurbish and revamp your equipment but to repair and significantly enhance it, enabling your operations to reach new levels of performance, efficiency, and reliability. With MCI, you’re choosing a partner committed to excellence, uniquely positioned to help you excel in an ever-evolving industry.
