Thiess recently signed a partnership and distribution agreement to deliver FLANDERS hybrid retrofit technology for mechanical-drive haul trucks.
The partnership it says “combines world-leading hybrid drive train technology, with Thiess’ global asset maintenance asset maintenance capability, engineering expertise, rebuild facilities and field delivery experience.” Thiess adds: “Rather than waiting for future battery-electric fleets, hybrid retrofit technology enables operators to reduce emissions from the assets they already own.”
The solution integrates FLANDERS power inversion, battery storage and intelligent control systems with existing truck platforms, creating a practical transition technology that improves both environmental and operational performance.
The retrofit of a Caterpillar 793D haul truck is now well underway. Following completion of the truck strip-down, testing and chassis remediation works, installation of the hybrid system components have begun. Current works include deck fitment, drive cabinet and battery cabinet installation, ACE assembly, and integration of the hybrid cooling and drivetrain systems.
Once the hybrid retrofit is complete, asset performance and economic modelling will be validated under real operating conditions. Subject to successful trial outcomes, Thiess will expand its hybrid retrofit fleet and demonstrate the benefits, ready to support large-scale deployment across the mining industry.
On the market introduction, Thiess adds that successful fleet decarbonisation begins with understanding where hybrid technology creates the greatest value. “Thiess works with clients to assess fleet age, rebuild schedules, haul profiles, production requirements and operating costs to identify the most effective hybridisation strategy.”
It says it can help customers navigate questions such as which trucks should be hybridised, how hybridisation can align with a scheduled rebuild, and if it makes sense to combine hybridisation with other technology upgrades such as automation and idle management. Thiess also looks at what productivity and fuel savings can be achieved, and what these benefits deliver for a project in a $/tonne output.
It adds: “For many operations, deeper haul profiles generate the greatest benefits, making financial modelling and fleet analysis critical before implementation.”
The hybrid retrofit systems are available for order today – and Thiess points out that intelligent idle management is already delivering measurable fuel savings, while autonomous haulage has been proven in mining operations for years. “Together, these technologies are helping reshape the future of fleets.”
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