Success Stories

Real Results from M&F Trading's Integrated Solutions

Case Study 1: Mining Sector

Optimization of Conveyor Belts in a Coal Mine

The Challenge

A large coal mine in Mozambique operated with an old conveyor belt system suffering frequent breakdowns. The conveyor lines had constant stoppages for bearing repairs and replacement of damaged idlers. Production was regularly interrupted, causing ship loading delays and penalty costs.

Initial State: ~85% availability, undersized idlers, worn pulleys, outdated motors, reactive maintenance only

Our Solution

Phase 1: Drive & Mechanical Upgrade

New SEW-Eurodrive gearmotors on main drive pulleys
Variable frequency drives for smooth speed control
Moret Mining idlers and support structures
Re-lagged and realigned head/tail pulleys
Impact beds at loading zones

Phase 2: Monitoring & Lubrication

Vibration and temperature sensors at critical points
Data acquisition for predictive maintenance
Automatic lubricators on main bearings
Knowledge transfer to maintenance team

Results Achieved

97%

Conveyor Availability
(from 85%)

+20%

Throughput Increase

-30%

Maintenance Costs

-40%

Downtime Reduction

Client Testimonial: "Since we implemented M&F's solutions, our equipment availability has improved dramatically. The condition monitoring system allows us to plan maintenance properly, and we've eliminated costly ship delays."

Case Study 2: Food & Beverage

Automation and Upgrade of a Beverage Bottling Line

The Challenge

A beverage company needed to increase production by 50% at one of its soda bottling plants to meet growing market demand. The existing line had limited capacity with 1990s equipment, showing inefficiencies and long downtime for format changeovers.

Pain Points: Frequent micro-stops, inconsistent filling, unexpected breakdowns, low OEE (60-70%)

Our Solution

Automation Upgrade

SEW stepper motors on bottle feeders
Gearmotors on belt conveyors
Servo drives on labeling systems
Central PLC control with cascade VFDs
Coordinated speed control across line

Reliability Improvements

Food-grade bearings for sanitary operation
Vibration/temperature sensors on key motors
Online monitoring system with alerts
Automatic lubrication systems
Operator training on new HMI system

Results Achieved

+50%

Bottling Speed
(10k to 15k bottles/hour)

85%+

OEE Achieved
(from 60-70%)

Zero

Production Bottlenecks

Impact: The modernization enabled the factory to meet market demand, with precise filling and synchronized conveyors reducing product waste. The automated quality control virtually eliminated defective products.

Case Study 3: Ports & Logistics

Increasing Efficiency in Port Operations – Bulk Cargo Terminal

The Challenge

A Mozambican port terminal specializing in bulk cargo (fertilizers and grains) was struggling to meet throughput targets. Infrastructure that had been in operation for decades resulted in below-target ship loading rates. The terminal risked losing contracts and faced safety incidents from abrupt equipment stoppages.

Requirements: Increase loading rate by 15%+, improve predictability, handle corrosive marine environment, minimize operational downtime

Our Solution

Equipment Modernization

High-efficiency SEW motors (IE3) on ship loaders
VFDs for soft starts and speed adjustment
Moret idlers/pulleys with anti-corrosion treatment
Belt scrapers and alignment systems
Misalignment and speed monitoring

Control & Monitoring

Sealed bearings for dusty environments
Centralized lubrication system
SCADA system for real-time monitoring
Visual/audible alarms for operators
Overnight installation during vessel windows

Results Achieved

+20%

Loading Rate
(exceeded 15% target)

-50%

Mechanical Failures
(first 12 months)

Zero

Safety Incidents
(material spills)

<1.5yr

ROI Period

Client Feedback: "M&F's technical competence and coordination were crucial. Many tasks were executed in short overnight windows between vessel operations, requiring precise logistics. The port is now competitive with the best regional terminals."

What Makes M&F Projects Successful

Integrated Approach

Combining drives, mechanics, and monitoring for holistic solutions

Local Expertise

On-site support and knowledge transfer to client teams

Minimal Disruption

Phased implementations during maintenance windows

Measurable Results

Clear ROI with documented performance improvements

Ready to Transform Your Operations?

Let M&F Trading bring the same integrated approach and proven results to your facility.

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