Equipment manufacturers underscore emissions reduction at bauma

Six months after the global mining industry gathered in Las Vegas, NV for MINExpo International the leading original equipment manufacturers (OEMs) were congregated again, this time in Munich, Germany for bauma 2025, held April 7-13. In 2022, an incredible 495,132 visitors from more than 200 countries attended this show that is a showcase of mining and construction equipment. Three years later, mining was again one of the focal points of the show, where more than 3,500 exhibitors from 57 countries presented their exhibits, innovations and trends. For many OEMs, bauma represents an opportunity to introduce the latest and greatest equipment. The following is a small sample of some of the equipment that was on display. Liebherr Decarbonization is one of the main focuses of this year’s bauma exhibition. In fact, the majority of bauma 2025’s key topics are related to emissions reduction, with one specifically focusing on the challenge of mining in an environmentally conscious way while also meeting the increased demand for raw materials. The Liebherr Group used bauma to showcase two zero-emission mining solutions — the T 264 battery-electric truck and the R 9400 E electric excavator. “Electrification is an important part of our strategy for offering fossil-fuel-free options for all of our mining equipment by 2030,” said Oliver Weiss, executive vice president of R&D and production for Liebherr Mining Equipment SAS. “The solutions we are bringing with us to bauma this year highlight the incredible strides we’ve made in this area.” The T 264 battery-electric truck represents the culmination of years of hard work within a partnership between Liebherr and mining company Fortescue, showcasing the value of working hand in hand with industry partners. It is a 240-t (264-st) mining truck powered by a 3.2-MW battery, which was developed by Fortescue Zero, Fortescue’s technology arm. The battery-electric truck supports both static and dynamic charging, and options for both were on display at bauma. The stationary fast-charging solution at the Liebherr booth was developed by Fortescue. It delivers up to 6 MW of power, enabling the T 264 to charge in under an hour. Liebherr also showcased the Liebherr Power Rail, a class-agnostic dynamic charging concept based on Liebherr’s proven trolley bar technology. The T 264 was also outfitted with the Autonomous Haulage Solution (AHS), another development courtesy of the Liebherr–Fortescue partnership. The AHS includes an energy management system that coordinates the static recharge assignments for battery-electric trucks and ensures the charger is fully utilized without causing queuing on site. The T 264 enters validation in 2025. Liebherr will deliver 360 units of the trucks to Fortescue’s Australian operations before the end of 2030. As for the fully autonomous battery-electric solution, the validation process will begin in 2026. The R 9400 E 350-t (385-st) electric excavator combines Liebherr’s more than four decades of expertise in electric excavator development and manufacturing with the latest innovations from the mining product segment. The R 9400 E is equipped with Liebherr’s cable reel solution, which offers up to 300 m (984 ft) of autonomous cable management to enhance manoeuvrability for increased operational flexibility. Feedback from customers has confirmed that the R 9400 E demonstrates the same power and productivity as its counterpart powered by an internal combustion engine. Running the electric excavator on site also reduces operational costs, and it emits zero greenhouse gases during operation. “We have come a long way since the last bauma exhibition in 2022. It has been thrilling to see the progress of the past three years up close, and we are looking forward to engaging with customers and fans alike at the show about all that we’ve accomplished and all we have planned for the years to come,” said Jörg Lukowski, executive vice president of sales and marketing for Liebherr-Mining Equipment SAS. Caterpillar Marking its 100th anniversary, Caterpillar Inc. focused on “The Next 100 Years” of innovation and sustainability at bauma 2025. Caterpillar used bauma 2025 to show its new Cat 775 off-highway truck, spotlighting the company’s ongoing leadership in technology and autonomous capabilities. The machine is the first next-generation design of off-highway trucks for the company. Distinguishing it from the previous 775 models, the 65-t (71-st) payload hauler is engineered to enable fully autonomous capabilities in the future. “The design of the Next Gen 775 represents a significant leap forward in off-highway truck technology, offering unmatched power, efficiency and safety features,” said Tony Fassino, group president of Caterpillar Construction Industries. Caterpillar is leveraging its current autonomous hauling system, Cat MineStar Command for hauling, already at work at mine sites throughout the world, and scaling the system’s processes and technology to meet the specific needs for quarry operations. “We are using the lessons learned from working with our U.S.-based customer, Luck Stone, where we have MineStar Command for hauling installed on four Cat 777 trucks,” said Denise Johnson, group president of Caterpillar Resource Industries. “The shift to the aggregates industry, where we are automating fewer trucks that don’t haul material 24 hours a day, is helping transform our technology and processes to manage smaller operations.” The Cat 775 next-generation truck has a planned introduction in 2026. Autonomous capabilities with MineStar Command for hauling are currently under development, and a release date will be announced at a later date. The 775 features an innovative new frame design that helps to optimize payload weight, a refined suspension for improved ride and handling, and advanced safety features like the 360-degree surround cameras and Cat Detect radar system to deliver superior performance and a safer and more comfortable operation. “Compared to previous models, our next-generation 775 off-highway truck features an industry-first frame design that reduces empty weight, delivering the potential for larger payloads and lower fuel burn. Plus, its 10 percent more body volume and improved turning radius helps to boost productivity and performance,” said David Holthaus, senior engineer and team lead for the Cat 775. With more body volume, the truck’s new frame is optimized for weight distribution and structural efficiency. Compared to the 775G series truck, there is nearly 30 percent less welding to minimize the risk of cracks and improve frame life. Less internal welding and ease of frame repairability help lower costs to maintain the new 775 over an estimated 40,000-hour truck life. Its redesigned suspension boasts a lower center of gravity. It has shown to deliver better handling than previous designs, and an updated turning radius enhances on-site maneuverability. Improving service life, the truck experiences less bouncing on the tires and driveline, and the operator feels less vibration and energy feedback into the truck. The truck is powered by the 615-kw (825-hp) Cat C27 engine and comes in different emissions configurations to meet different global regulations. The U.S. EPA Tier 4 Final/Stage V version displayed at bauma offers better fuel efficiency than previous models, with advanced electronic powertrain controls that deliver faster cycles and reduced road maintenance. The truck’s enhanced ride and handling allow for higher speeds on curves and driving in higher gears, which directly reduces fuel consumption during the cycle. The truck’s new cab is designed for efficiency and equipped with features to automate functions. The large windows give the operator visibility to the work area and surroundings. Automatic cab temperature controls and the Cat next-generation deluxe seat are designed to help to improve operator comfort. Its 360-degree surround cameras with object detection alerts operators to hazards within the immediate vicinity, making it easier to safely operate the new 775. Cat Detect combines radar and camera systems to automatically detect hazards within critical areas around the truck — primarily the front, rear and turning radius on each side. Multiple key maintenance and service contributors have been reduced with the new truck design. The next generation of enhanced serviceability incorporates extended-interval filters with ground-level access, ground-level lockout features and a serviceable suspension. Its design is fire-suppression-ready to simplify system installation. The ability to access and analyze accurate real-time data enables faster diagnostics and enhances the ability to predict and prevent machine failure. New for the 775, remote flash and troubleshooting capabilities help boost truck availability. Remote flash instantly provides access to the latest software updates and enables the updates to be scheduled and executed at a time that does not interrupt the production schedule. Remote Troubleshoot enables the dealer to perform diagnostics remotely while the truck is still in operation. Komatsu Komatsu showcased innovative advancement in electrification at bauma 2025. In collaboration with Dimaag, Komatsu introduced the industry’s first Mobile Megawatt Charging System (MWCS). Designed for construction and off-road applications, this cutting-edge system allows charging directly at the point of use, minimizing downtime and enhancing operational efficiency. This debut marks a significant step toward sustainable solutions in heavy industries, aligning with Komatsu’s goal of achieving carbon neutrality by 2050. The MWCS features a compact DC-DC converter and a durable energy storage system, both enhanced by an advanced thermal management system. This ensures safety and longevity during high-power delivery. With its modular design, the system can scale to meet varying power demands, making it a versatile solution for construction sites and beyond. Its mobility, supported by four-wheel drive and steering, allows it to maneuver through challenging environments with ease. Ian Wright, vice president of engineering at Dimaag and Tesla co-founder, said about the system’s potential, “Our collaboration with Komatsu brings practical electrification solutions that outperform diesel equivalents while reducing costs.” Taisuke Kusaba, Komatsu’s chief technology officer, echoed this sentiment, highlighting the partnership’s role in overcoming electrification challenges like infrastructure costs and power supply needs. Sandvik Sandvik introduced new products for surface and underground mining at bauma. The Sandvik DD422i and Sandvik DD422iE Dual Controls jumbo development drills offer improved safety and efficiency with new ground support options. The latest pumpable resin system, featuring mineral bolt technology from Sandvik Ground Support, now supports three bolt types: (1) resin-grouted rebar bolts, offering maximized productivity at lowest unit cost, (2) Versabolt, adding great energy absorption for dynamic ground support and (3) DSI hollow bar and self-drilling bolts, for post-grouting installation with the highest level of productivity and safety, even in difficult ground. It is ideal for deep mining, block caving and rehabilitation works. “With the new pumpable resin package for Dual Controls, we are not just improving bolt installation, we are transforming it,” said Anssi Kouhia, product manager for ground support at Sandvik. “It is faster, safer and more consistent, giving operators full control and confidence underground.” The system includes bolt loading from a safer area, fast and mechanized resin injection via the operator display, and enhanced safety features such as boom movement prevention, access protection and clear status indicators. “This is a step change in ground support —safe, efficient and seamlessly integrated with our Dual Controls concept,” said Simon Morrissey, product manager for underground drilling at Sandvik. Sandvik Mining and Rock Solutions also introduced a comprehensive update of the Panter DPi series drill rigs that provide an upgrade with higher uptime and efficiency, more meters and maximum comfort.Sandvik said that with more than 2,500 units delivered since 2008, the Pantera DPi family is the market leader in production top hammer drilling in openpit mines, particularly gold mines, in the 89-mm to 178-mm (3.5-in. to 7-in.) hole size range. The key components of Pantera DPi have been redesigned for higher reliability and availability. The rig can achieve extended maintenance intervals and longer service life, even in extreme heat or harsh Arctic conditions, thanks to the improved circulating shank lubrication (CSL) lubrication system, leaf chain feed, stronger boom design, larger engine filters, drill heating system and heavy-duty accumulator. The new C9.3B Tier 3 engine improves fuel economy by saving up to 5 L (1.3 gal)/h. Coupled with the new digital functionalities of the My Sandvik customer portal, including consumables logging, access to machine health statistics and drilling data, the updated Pantera DPi drill rigs help mine operators to achieve higher productivity and more effective operating expense management.

Equipment manufacturers underscore emissions reduction at bauma

Authored by: William Gleason

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