At Mount Thorley Warkworth (MTW) in the Hunter Valley, New South Wales, every investment is evaluated against four key priorities: productivity, reliability, sustainability and the long-term wellbeing of the communities surrounding the operation.
As the mining industry continues to navigate the transition towards lower-emission operations, sites are looking for practical ways to improve efficiency while supporting their sustainability goals. For Yancoal, investing in a fleet of 18 Cat 794 AC Electric Drive Mining Trucks represented an opportunity to do exactly that.
For MTW General Manager Cris Shadbolt, the decision wasn’t simply about introducing new equipment – it was about building a more resilient, efficient and sustainable operation for the future. He stated: “Sustainability is extremely important in Yancoal’s future plans…and our social license to operate is critical. Our investment in the 794s came through a rigorous process of looking at what’s going to be the best fit for us here under our Tier 1 excavator fleet.”
Caterpillar dealer WesTrac says the results are already delivering tangible benefits, with fuel consumption improving by approximately 10%, alongside gains in productivity and operational performance.
When Yancoal began evaluating its next haul truck fleet, WesTrac says the focus wasn’t solely on production. The team was looking for a solution that could integrate seamlessly with its existing fleet, while delivering measurable improvements in fuel efficiency, productivity and long-term performance.
WesTrac: “The Cat 794 AC’s electric drive technology quickly emerged as a strong fit, combining the payload capacity and reliability required for a large-scale mining operation with the potential to significantly improve fuel efficiency.”
For a site producing around 18 Mt annually, even modest improvements in efficiency can create long-term benefits. Lower fuel consumption not only reduces operating costs but also supports Yancoal’s broader environmental objectives through lower emissions and more efficient energy use.
Since introducing the 794 AC fleet, the benefits have extended well beyond fuel savings. Matched with the site’s existing shovel and excavator fleet, WesTrac says the trucks have integrated seamlessly into daily operations, helping maximise payloads, reduce passes and improve haul cycle efficiency.
According to Yancoal MTW Maintenance Manager Warwick Gloster, operator feedback has also been exceptionally positive. “The 794s have performed outstanding…operators really like them.”
The trucks’ responsiveness, improved visibility and ease of operation have contributed to strong adoption across crews, while their performance on ramps and through haul cycles has seen a boost in productivity.
Shadbolt: “The 794s are quick to spot, quick to take off, and their ramp speeds have been excellent with optimal payloads. The 794s are one of the last trucks to park up in wet weather and one of the first to get going again.”
For a 24/7 operation, that resilience translates into greater uptime, improved productivity and more consistent operational performance.
While the full benefits of electric drive technology continue to evolve over time, Yancoal is already seeing encouraging results. “What we’ve seen is around 10 percent fuel burn improvement in these new 794s, Gloster noted.
For the MTW team, those gains represent more than improved operating efficiency. Reduced fuel consumption lowers operating costs while contributing to lower greenhouse gas emissions, supporting Yancoal’s long-term environmental commitments. Combined with onboard technology and fuel management systems, the site now has greater visibility into fleet performance, enabling more informed decision-making and continuous improvement.
WesTrac: “It’s an investment that is delivering value today while helping prepare the operation for the next generation of mining technologies.”
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