When choosing machinery, mining company Imerys recognises that factors such as productivity, reliability, and the ability to operate safely in demanding conditions play a decisive role in determining their place on the site.
In the ground, it appears within soft, soapy, flaky mineral masses or veins, often white, pale green, grey, or brownish, with a greasy feel and dull to shiny appearance. It’s also easily scratched because it’s the softest mineral known.
This is talc: a naturally occurring substance formed from magnesium, silicon, and oxygen. Its supple composition makes it valuable as a lubricant and filler, used in paper, paints, plastics, ceramics, and rubber.
On a global scale, most of the talc ore is mined by Imerys, a French multinational corporation that was founded in the late 19th century. Evolving through mergers and acquisitions, it has become a major producer of specialty minerals.
The Imerys portfolio includes the Three Springs Talc Mine in Three Springs, Western Australia, the largest talc reserve in the Southern Hemisphere.
The deposits were first discovered in the area in the 1940s, and mining began soon after by the Western Mining Corporation, which operated the site for many years before selling it to The Luzenac Group and then to Rio Tinto in 2001.
In 2011, Imerys expanded its presence in the talc market by acquiring Three Springs Talc from Rio Tinto and several of its major mining operations.
Three Springs to mind
Today, the mine produces roughly 110,000 tonnes of talc annually, which is sold into various industrial markets. The ore body is rich in magnesium carbonate and known for high-purity, high-brightness talc.
We ventured out to the site to speak to Operations Manager Gary Turley and Mines and Process Manager Rebecca Bussenschutt about the mine and the equipment that made it tick.
The first thing we see is the sophisticated talc processing plant, which receives raw talc ore extracted via open-pit methods and processes it — crushing, screening, and beneficiation — to produce tailored talc products for use in paper, plastics, ceramics, paint, and other applications.
“Imerys is the world’s leading supplier of mineral-based specialty solutions for the industry, with annual revenue of 3.6 billion euro and 12,500 employees in 40 countries,” Rebecca said.
“It draws on its understanding of applications, technological knowledge and expertise in material science to deliver solutions that contribute essential properties to customers’ products and their performance.
“As part of its commitment to responsible development, Imerys promotes environmentally friendly products and processes, while supporting its customers in their decarbonisation effects.”
Rebecca said the site was predominantly farmland when the talc riches were discovered.
“Some local farmers were looking for a water source for their livestock and came across unusual rocks, which were then discovered to be talc,” she said.
“They started underground mining in 1948, and we’ve been mining here ever since.
“We’ve moved with the times, coming from underground to now surface mining, and we’ve been through a number of pits, currently on our fourth, and planning a fifth.”
Komatsu is king
There’s little doubt as to the preferred make of equipment that drives the Imerys operations. Of the 13 machines used on the site, 10 of them are Komatsu.
These include two Komatsu large hydraulic excavators, which offer excellent digging performance: a larger PC1250 excelling in sheer force, and a smaller PC950 that integrates modern technology for cost savings and safety.
“We also have a number of dump trucks, such as a HD605-8, HD605-10, HD465-7 and HD465-10,” Gary said.
“The other equipment we have includes WA500 and WA600 large production wheel loaders.”
The relationship with Komatsu began in 2004, when the mine tested the waters with the purchase of two HD465-7 trucks and a PC1250 excavator.
“It’s been 21 years now and the partnership keeps growing in strength,” Gary said.
“We’ve had such good reliability from the Komatsu equipment we’ve had over that time.
“And not only were we impressed with the machines, but we also appreciated the back-up service we received from the Komatsu branch at Geraldton, which is close by.
“Komatsu is always available to help us out. It’s only a phone call away to get tech support and other services that are fast and reliable.
“They’ve got great experience. They’ve got technicians who’ve been looking after us for many years. They do all the servicing, supply all oils, and generally look after the equipment.
“Getting parts is not a problem. If they’re not in stock in Geraldton, we get them overnight straight out of Perth. It’s never too much trouble.”
Ensuring that Imerys is well looked after is Komatsu Sales Account Manager Tony Didio, who only took on the role in 2024, but is well aware of the mine’s legacy and connection with the manufacturer.
Tony took the time to highlight a couple of the machines that were working hard during our visit: the HD605-10 truck and the PC950 excavator.
“The truck was only delivered in March last year and is suitable for Imerys for a number of reasons,” he said.
“The quarry tray on the back will easily hold 40 cubic metres of dirt, which is equivalent to 62 tonnes of material inside the tray.
“We also specced up many safety features on this particular build for Imerys, such as auto grease and fire suppression systems, and we included a fast fuel and lubrication evacuation set-up on this particular truck.”
Lubrication evacuation is the process of quickly and cleanly removing used oils, coolants, and other fluids from machinery or vehicles, typically using specialised vacuum systems or valves that create suction or pressure to transfer fluids from the equipment into a waste container, minimising spills and mess for safer, faster maintenance.
“So there is less likelihood of a spill happening because they’re auto-sucked and replaced,” Tony said.
The PC950 was another new addition to the fleet, also acquired last year.
“It’s a brand-new model for Komatsu. It sort of sits in between the PC850 and a PC1250, suitable for the 95 to 100 tonne class range,” Tony said.
“This particular machine that we delivered has been fitted with a six cubic metre rock bucket, which has got the extra armour on the front to deal with the material that comes out of the quarry.
“And like the truck, the 950 came out of the factory with a lot of other safety features.
“It’s got a full Tier 4 certified engine, which meets the EPA regulations for lower carbon emissions.
“The PC950 comes with a standard walkway and safety rails to the cabin area, and also along the top deck, enabling any operator or field service technician to comfortably walk around on the machine without the fear of falling from such a height.”
Tony said that the PC950 and the HD605 were “very well paired machines”.
“They work well together in a quarry environment because of the sheer size of the trays and the placement of the bucket,” he said.
“The number of passes from the 950 into the HD605 is a good fit, making it easy to fill up that 40 cubic metre tray with 62 tonnes of material on it.”
The safety features were also welcomed by Gary and Rebecca.
“As Tony said, they have a hydraulic access stairway, wide walkways, and fall prevention handrails for easier, safer access and maintenance,” Gary said.
“Other key operator safety additions include auto-locking control levers, an engine shutdown secondary switch, and a retractable seatbelt with a reminder, reducing fatigue and preventing accidents.”
Rebecca said the cab layout was hard to fault.
“We’ve got a KomVision 360-degree camera system and additional mirrors,” she said.
“The operator is looked after with a comfortable driver’s seat and passenger seat, while there is LED lighting, including around the central maintenance area, which improves visibility.”
Tony said the fact that the older machines were still being used was testament to the Komatsu reliability.
Other points that made Komatsu machines a good buy included the purchase price and the life cycle costs, offering sound return on investment.
Tony said that Komatsu also had a specialist team in Perth that engaged with Imerys on the Smart Quarry system: the company’s fleet management solution that focuses on site management, production optimisation, machine health monitoring, and proactive maintenance and safety.
“We help set up and maintain the dashboards to access the data and telemetry that’s provided from Smart Quarry, to enable operators to gain better efficiency and productivity through that software,” he said.
“Our strategy with Imerys also involves looking at their replacement machine strategy over the next 12 to 18 months on other aged equipment, and how we can replace it with newer models that show increased safety equipment as well as productivity gains, whether it be through fuel savings or the machines.
“We will work to ensure that we meet Imerys’ current policy and standards around improving sustainability and emission controls, as well as lifting production and efficiency.”
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