The so-called “Tollmet Process” was specifically developed to overcome typical constraints of conventional gravity separation systems.

It proved to increase recovery of minerals at levels beyond 300% when compared to the conventional systems, which it replaced. Furthermore, the final product quality is also improved in order to provide clients with a more efficient process containing little or no recoverable matter in its final disposable waste streams.

Tugela’s Fine Material Separation (FMS) process pioneered the way, and still sets the benchmark, in which Gravity Concentration of liberated mineral particles between 20 micron and 3 mm is conducted in numerous applications.

Conventional systems, due to its inherent inefficient means, would normally narrow treatment possibilities down to within particle size ranges of 0.1mm to 1mm. In some cases, the necessity of an additional process (for treatment of 1mm to 3mm particles) diminishes through the implementation of a single “Tollmet Process”.

The essential benefits can be summarised as follows:

  • Improved Recovery Yield
  • Improved Product Grade / Cleanliness
  • Redundancy of the necessity of conventional dual processing for the full 0.1mm-3mm particle size range, by the implementation of a single FMS.

Historical track reference and independent comparative test work results, as executed by some of our clients, will be able to verify the statements that are made herein, and can be disclosed (for verification purposes) on request based on conclusion of a confidentiality and non-disclosure agreement.


Fully-fledged pilot test work facilities provide Tugela with the essential ability to alter and develop processes.


No financial proposal is done to a client prior to and without executing the essential upfront test work.


The Coarse Material Separation (CMS) process is a developed derivative of conventional Jigging.

Several test prototype and production units were implemented with the purpose of overcoming the negative effects of the compressive nature of air (in air-pulse Jigs) and the sinus-wave-type effect (as presented in direct pulsating Jigs). This technology overcomes these effects, and is still lacking production maturity, but promises process advantages not to be overlooked.

The CMS Technology is applicable to material particle sizes varying between 3mm and 30mm. Typical size ranges, per treatment stream, would be 3mm-8mm, 8mm-20mm and 20mm-30mm. This technology, developed in-house, has a successful track record and, while Tugela’s primary focus is currently on utilising its FMS, this will become another important pillar upon which the company’s differentiated business platform will be based.

Test work facilities at Tugela’s sites in Mpumalanga and North West Province provide accurate process data on samples processed.



Tugela’s dedicated team of Metallurgical and Mechanical Engineers have been intimately involved in the aspects of process design, manufacturing, and implementation of Dewatering (Solid / Liquid Separation) equipment, such as Thickening, Flocculation, Coagulation, and Filtration.


Water regeneration is an integral element of Tugela’s processing operations


It can be put to good use where clients require improved management of water resources. It requires proper design and careful attention in order to prevail process efficiency and water management.

Dewatering requirements are assessed, and, in some cases, Tugela’s in-house developed Thickener system is employed. Tugela has, on rare occasions, replaced Thickener systems to improve Thickener performance of their valued clients.


As a production and SHEQ driven company, the inhouse-designed Build, Own, Operate and Maintain (BOOM) of run-of-mill type operations also fall well within Tugela’s parameters of expertise.

The following list of general processes categorises Tugela’s expertise in terms of specification, design, implementation, management, operation, and maintenance:

Structural and layout preliminary design of processing plants

Materials handling

  • Feeder bins
  • Grizzly Systems
  • Feeder Breakers
  • Vibratory feeders and limpet vibration
  • Conveyor Belt systems
  • Chutes
  • Belt scraping and cleaning systems

Dry and Wet Material Screening


  • Cone
  • Jaw
  • Roller
  • Vertical Spindle

Pumping, sumps, laundering, piping, and valves


  • Sizing
  • Desliming
  • Dewatering

Spirals (and modification thereof)

Elutriation / classification (and modification thereof)


Dry Magnetic Separation

  • Electromagnets
  • Pulley Magnets
  • Suspended Self Cleaning Magnets

Rare Earth Magnets

  • Pulley Magnets
  • Suspended Self Cleaning Magnets


  • Thickeners, Feedwell Design and Implementation
  • Flocculant Make-up and Dosing plants / systems