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A typical mineral processing plant operates a SAG mill (diameter 10.4 m, length 5.6 m) in a high-throughput grinding circuit. The mill processes highly abrasive ore with lump sizes up to 200 mm. Liner replacement is a critical operational factor directly affecting mill availability and production cost.
In many mineral processing plants, conventional rubber mill liners often suffer from uneven wear – feed-end liners and discharge components wear significantly faster than the rest of the mill. This creates “weak links” that can force premature shutdowns.
Additionally, as liners wear, the internal mill volume increases, causing throughput to rise and energy consumption per ton to fluctuate. This requires constant recalibration of load cells to avoid operational inefficiency or equipment overloading. Overall, processing plants require a liner solution with consistent, predictable performance to extend maintenance intervals and stabilize production.
Strudex’s engineers adopt advanced material science and application-specific customized design. After in-depth analysis of the plant’s mill operation dynamics, wear patterns and ore physical characteristics, we deliver a targeted and optimized liner solution package, covering three core advantages:
A high-tensile, wear-resistant exclusive Strudex blend is specially formulated for high-abrasion ore working conditions. The material features excellent anti-wear performance while maintaining good elasticity, which can effectively absorb grinding impact energy and reduce structural wear of liners.
We adopt enhanced tapering design for high-impact areas including the mill feed end and lifter bars, which optimizes internal slurry flow status and energy absorption efficiency. Meanwhile, key discharge components are redesigned and matched to achieve synchronous service life with main shell liners, eliminating partial wear weakness.
All liners are produced via precision moulding in strict accordance with mill equipment specifications, realizing uniform overall thickness and stable, consistent performance of the complete liner set.
By the end of July 2025, the customer completed the full installation of Strudex cone liners. The high precision of our manufacturing process was fully verified on site: the liners were closely assembled with extremely small gaps between adjacent panels. The tight fitting effect effectively prevents ore and slurry material ingress, avoids accelerated local wear, and guarantees the long-term stable service life of the overall lining system.
After two months of continuous stable operation, the customer gave highly positive feedback on the performance of Strudex cone liners. The on-site operation effect was far better than expected. Impressed by the reliable initial performance, the mine immediately placed an order for an additional set of cone liners as spare parts, reflecting high recognition of the product’s stability and service life potential.
At the 8-month operation milestone, the customer provided detailed operational evaluation data. The liners maintained excellent overall quality, with no premature wear, deformation or performance attenuation. Relying on the outstanding field performance, the mine purchased a third set of cone liners for spare use again, further confirming its full trust in Strudex’s product quality and manufacturing capacity.
After nearly 12 months of uninterrupted operation, the product achieved the most critical performance verification. The mining operator expressed full satisfaction with the comprehensive performance of Strudex cone liners. All liners remained in good working condition without abnormal wear. The customer finally formulated a replacement plan for the first set of liners at the 18-month operation mark, which greatly exceeds the service life expectation of conventional liners in high-abrasion SAG mill working conditions.
The customer’s continuous repeat orders fully reflect stable product performance and high brand recognition. Up to now, the customer has purchased three sets of Strudex cone liners (one installed set + two standby sets). The first set of liners is expected to reach 18 months of service life, establishing a long-term trust cooperation relationship.
This successful case summarizes four core advantages that bring excellent operational benefits to customers:
Durable Material Performance: The combination of Strudex’s proprietary rubber compound and optimized structural design delivers strong durability for long-term SAG mill grinding operation. The first set of liners still operates stably after nearly 12 months of continuous service.
Precision Engineering Design: Strict dimensional control in the production process ensures seamless on-site installation with minimal gaps between liner panels, effectively avoiding material ingress and prolonging overall service life.
Customized Manufacturing Capability: Strudex can carry out personalized production according to customer equipment parameters and working condition demands, including complex wear-resistant structural designs, with flexible engineering strength and reliable production capacity.
Strict Quality Assurance System: Pre-delivery trial assembly inspection is implemented for all products to ensure all components meet dimensional and assembly standards, eliminate on-site installation delays, and ensure rapid and stable commissioning.
Founded in 2002 (formerly known as Huanyou Rubber Products Co., Ltd.), Strudex has focused on the R&D and production of rubber wear-resistant products for 30 years. We have in-depth insight into various pain points and challenges of mineral processing and grinding operation. With long-term adherence to technological innovation and quality control, we have become a reliable long-term partner for global mining enterprises.
Different from most peers that purchase ready-made rubber compounds, Strudex is equipped with a professional in-house rubber mixing workshop, realizing independent formulation research and self-mixing production of all rubber materials. We fully control every link of material formulation, bringing multiple core benefits:
Strict Quality Consistency: Independent control of the whole mixing process ensures stable quality of each batch of materials and unified product performance.
Free Custom Formulation: For complex and high-abrasion working conditions, we can independently develop targeted rubber formulas without relying on external suppliers.
Efficient Response Capability: In-house mixing avoids the cycle delay of external custom material procurement and quickly meets customer personalized order demands.
Cost Control Advantage: Eliminate intermediate supplier markup costs and deliver high-cost-performance products directly to customers.
Proprietary Technology Protection: Independent research and development of exclusive wear-resistant formulas to form differentiated product advantages and ensure superior working performance.
Independent rubber mixing technology is the core foundation of Strudex’s high-quality, high-durability wear-resistant products.
Strudex implements full-link rigorous quality control covering raw material incoming inspection, production process monitoring and finished product performance testing. We are equipped with advanced professional testing equipment and strictly abide by standardized quality management systems to ensure all products meet and exceed customer technical specifications.
Strudex wear-resistant products are exported to mining projects in Russia, Germany, the United States, Kazakhstan, Spain, Brazil, Chile, Australia and other countries and regions. Our modular rubber screen panels and mill liners are fully compatible with mainstream international brand equipment including Metso, Schenck, Multotec and Selm, which fully verifies our standardized engineering design strength and industry recognition.
This SAG mill cone liner application case fully demonstrates Strudex’s professional strength in customized precision rubber wear-resistant solutions for mining grinding circuits. With dual support of advanced material technology and sophisticated manufacturing process, our products achieve excellent and stable field performance.
The customer’s repeated orders and phased positive operation feedback prove that Strudex products fully exceed the industry average level in actual high-abrasion mining working conditions. The 18-month expected service life of the cone liner greatly breaks the industry service life benchmark of similar products, effectively solving the pain point of frequent shutdown and replacement caused by uneven wear of traditional liners.
For mining enterprises that need high-durability and high-performance wear-resistant supporting solutions for grinding systems, Strudex relies on rich industry experience, independent R&D and manufacturing capabilities and perfect quality assurance system to help customers optimize mill operation efficiency, reduce equipment maintenance frequency and lower overall operation cost.
