Table of Contents
South Africa has established itself as a global hub for the production of Weir’s advanced ENDURON® Elite banana screens. These “banana screens” are a type of vibrating sieve used in mining and mineral processing, named for their curved shape that improves material separation efficiency. The Alrode facility in Gauteng has undergone major infrastructure investment and is now the world’s first site dedicated solely to manufacturing this innovative range.
The recent expansion at Alrode adds 1,600 m² of covered production space, equipped with two powerful 63-ton gantry cranes that operate at a clearance height of 18.5 metres. This upgrade was prompted by a significant £53 million contract from Barrick’s Reko Diq copper-gold project in Pakistan, requiring the supply of fine grinding, separation, and tailings solutions.
One of the key features of the facility is a specially engineered “plinth” – a heavy concrete and steel foundation that absorbs intense vibration forces during product testing. This plinth, which required excavations reaching two storeys below ground, is essential for testing the screens’ durability and performance.
Production Capabilities
The Alrode expansion has enabled the creation of two dedicated assembly stations for the high-capacity double deck ENDURON® Elite screens. Each screen weighs nearly 50 tonnes, with deck dimensions up to 4.3 metres wide and 8.5 metres long. An “exciter” is the mechanical device that generates vibrations needed for the screens to separate materials, and the facility’s robust design ensures safe and efficient handling of these powerful components.
Thanks to advanced technology and a strong local supply chain, the Alrode team was able to manufacture the first two ENDURON® Elite screens even before the new production space was fully completed. Specialized equipment, including a laser facility capable of cutting massive 12 m by 5 m side plates, further enhances production capabilities. A targeted supplier development programme has strengthened local partnerships, ensuring quality and reliability throughout the process.
The new bays are designed to produce at least two ENDURON® Elite screens per month, without disrupting ongoing output of other models in the range. Production for the first half of 2026 is focused on fulfilling the Reko Diq contract, with plans to ramp up output as market demand grows. The facility is intentionally built to accommodate future upgrades and increased capacity.
Sustainability Initiatives
Weir’s Alrode plant is pioneering sustainability efforts within the company’s global operations. One notable initiative is the adoption of water-based paint for the expanded facility. Water-based paint, unlike traditional solvent-based options, emits fewer volatile organic compounds (VOCs), reducing harmful emissions during application. At Alrode, early trials have shown a measurable improvement: “Switching to water-based paint has cut VOC emissions in our process by over 40%,” says Alandré van Vuuren, Integrated Supply Chain Director.
Another significant sustainability effort is the use of renewable energy. The facility runs entirely on solar power generated onsite, except for the variable speed drive needed to start up the screens. This transition has resulted in a notable drop in carbon emissions. Van Vuuren explains, “With our solar power system, we have reduced our operational carbon footprint by nearly half, supporting Weir’s global goal of a 50% reduction by 2030.” These initiatives not only benefit the environment but also demonstrate Weir’s commitment to responsible manufacturing practices.
Economic Impact
The Alrode expansion has delivered broad economic benefits for South Africa. By prioritising local procurement, nearly all components and materials for ENDURON® Elite screens are sourced from South African suppliers. While most finished screens are destined for export, the facility’s activities boost local businesses and contribute to export earnings.
Job creation and skills development are central to Weir’s approach. The expansion led to around 40 new technical positions, including roles in screen assembly, hand-lining, and painting. Employees have benefited from upskilling programmes designed to foster career growth. Sipho, a newly qualified fitter, shares his experience: “Before the expansion, I was a general labourer. Through Weir’s training, I learned new skills and earned a formal trade qualification. Now I assemble screens that are shipped worldwide.” Another team member, Thandi, who moved from hand-lining to painting, says, “The water-based paint training not only improved my health but gave me confidence in my work. I feel part of a team that’s making a real impact.”
Alongside upskilling existing staff, Weir is creating opportunities for new entrants in lower-skilled roles, with a focus on developing their potential over time. Van Vuuren emphasises, “We are committed to responsible manufacturing and local development, ensuring that our growth supports both our people and the broader community.”
Through investment in cutting-edge technology, sustainable practices, and people-focused development, Weir’s Alrode facility is setting a new standard for manufacturing excellence in South Africa and beyond.
