Every machine eventually reaches a point where it starts to fail. More frequent downtime begins to appear, maintenance costs keep rising, spare parts become harder to source – and yet, somewhere at the back of your mind, there is still the awareness that this is a machine with plenty of work left in it. It simply needs proper attention and a professional repair.
At Minostar, we understand this very well. For years, we have been restoring the performance of roadheaders that have already been through a lot, but still have real operational potential. Our proprietary RESTART programme was developed in response to the needs of mining companies that want to extend the service life of their equipment, reduce costs and avoid multi-million investments in new machines.
We are not a large corporation with a call centre and forms that are difficult to get through. With us, you speak directly to people who know the job – specialists who personally supervise modernisation processes and can assess your machine with the eye of an expert.
If your roadheader is no longer coping as it should, but you feel that it has not yet reached the end of its working life – see what we can do with it. Sometimes, it really does not take much to get it back to work. In other cases, it is worth going further and not only repairing the machine, but also modernising and upgrading it so that it is even better suited to the needs of your company. In this article, we explain how our RESTART programme works in practice and what you can expect when working with us. Enjoy the read!
AM-75 EX-S roadheader during overhaul – own photograph
When the machine can no longer cope, but scrapping it would be a waste
As a company operating in the mining industry, you certainly know that moment underground when a roadheader that has served reliably for years begins to fail more and more often. It still works, but increasingly it spends more time standing idle than cutting, and you know very well that every further breakdown means not only repair costs, but also the significant cost of unplanned downtime. On the one hand, it would be a shame to scrap it, because it can still cut and was adapted to a specific mine roadway and specific operating conditions. On the other hand, spare parts are becoming harder to obtain, and a new machine is an investment that can turn the budget upside down.
This is precisely where support under the Minostar RESTART programme can make a real difference. We do not offer half-measures, but a genuine restoration of your machine to full working order – in a way that makes economic sense. Depending on the condition of the roadheader, we can carry out a comprehensive overhaul, modernise it or rebuild it to meet entirely new requirements.
How Minostar RESTART works in practice – step by step
The whole process – as is probably the case with every service in the world – begins with contact. Sometimes it is a phone call, and sometimes it is a message sent through the contact form. All you need to do is let us know that something worrying is starting to happen with your machine. Our Clients often send us photographs, a description of symptoms or details of specific damage. We analyse all of this, and when the situation requires it and it is, of course, possible – we come to the site. Our qualified specialists go underground, inspect the machine in its working environment and assess what can be done.
We then analyse the technical and operating documentation, check the condition of the structure, components and overall wear. On this basis, we select the most suitable RESTART variant. This may involve restoring the machine to its original condition (RESTORE), modernising selected parts, components or assemblies without significant interference with the machine’s parameters (REBUILD), or carrying out a deep rebuild that extends the machine’s capabilities (REMODEL). We always take into account the Client’s budget and expectations regarding the repair.
Moving on to the work itself
Once the scope of work, budget and logistics have been agreed together, we move on to the practical stage. We can organise transport ourselves, or you can handle it on your side – we remain flexible because we know that every situation is different. In every case, however, you receive a detailed action plan, full support and smooth communication at every stage of our work.
What we can do with your roadheader – RESTART programme variants
As part of the Minostar RESTART programme, we offer three variants of action. Each of them has been developed to meet different technical and operational needs of Clients from both the mining and tunnelling industries. From restoring the original functionality, through upgrading selected assemblies, to a comprehensive rebuild that may change the way the machine is used. Below, you will find the details of each option.
Overhaul of the crawler travel system in an AM-75 EX-S roadheader – own project
RESTORE – when you want to restore full machine performance without structural modifications
The RESTORE option is a general overhaul, also known as a restorative overhaul. In this variant, we restore the machine’s original parameters and operational value, without introducing significant changes to its structure, intended use or machine type. The entire process is carried out in line with current technical knowledge and good engineering practice.
This type of overhaul does not result in the creation of a new machine within the meaning of applicable regulations. The restored roadheader retains all safety features required by the original regulations under which it was first placed on the market.
This is the right option if you want to extend the service life of your machine, minimise the risk of failure and preserve the unique characteristics of a specific unit – without the need to invest in new equipment.
REBUILD – when you need modernisation but want to remain within the existing machine type
The REBUILD variant involves overhauling the machine through modernisation, with modifications applied to selected parts, components or assemblies – depending on the user’s needs. The modernisation may include, among other things, structural changes to the loading table, hydraulic system or water system, as well as the addition of new solutions such as an additional FOPS-compliant operator guard, remote control or a separate drive for the chain conveyor.
See how the Minostar RESTART program works!
Importantly, despite these changes, the modernised machine does not change its intended use or its basic technical parameters. It remains the same type of equipment, compliant with the manufacturer’s documentation, and does not result in the creation of a new machine within the meaning of applicable regulations – which means that there is no need to repeat the conformity assessment procedure. The introduced changes, for example to the mechanical structure, hydraulic system or water system, do not alter the machine’s functionality or technical parameters, and do not reduce the level of safety associated with the use of the roadheader, as required by the original regulations under which it was first placed on the market.
For each such rebuild, an additional risk assessment is carried out in accordance with the applicable PN-EN ISO 12100:2012 standard, allowing us to confirm that the machine’s safety level is maintained.
This is a solution for Clients who want to improve performance, increase reliability and reduce operating costs without giving up a structure they know and trust.
REMODEL – when you want to change the machine’s application range and extend its capabilities
The REMODEL option is the most advanced form of the RESTART programme. It involves a comprehensive rebuild of the machine structure, with the aim of extending its application range compared with the original condition described in the manufacturer’s operating manual. Such work may include significant modifications to structural elements, the addition of new functions or adapting the machine to working conditions other than those originally intended.
Loading table after overhaul in an MR-340X roadheader – own project
As a result of this process, the machine may be classified as a new product in accordance with current regulations. In such a case, new technical documentation is prepared, the operating manuals are updated, and the conformity assessment procedure is carried out again. As a result, a new declaration of conformity is issued.
REMODEL is a solution for users who own older machines, often without up-to-date documentation, and want to return them to operation – better adapted to the current realities of the plant, with higher performance and increased functionality.
With us, you do not wait for weeks – direct contact and faster decisions than with the competition
When we founded Minostar in 2014, we wanted to make sure it would not become just another international corporation. As the company developed, we managed to preserve that organisational structure. You will not find bureaucracy here that delays decisions and makes communication difficult. Instead of endless transfers and waiting for a response from the technical department – you speak directly to people who know the subject inside out.
On our website, you will find direct phone numbers to the people who run the company – people who supervise roadheader overhauls on a daily basis, know what roadheader operation looks like in a mine, and can provide practical, reliable advice. This makes the whole process faster and more specific: you describe the situation to us, and we already know what we are dealing with and what we can propose.
Cutting head after comprehensive overhaul – AM-75 EX-S roadheader
You do not have to wait for weeks for distant meeting dates, approvals or replies. If something can be done – we act. And if time is needed for assessment, we tell you straight away what we can do and when. This is the partnership-based approach appreciated by our Clients and the one that has guided us from the very beginning.
In addition to efficient communication, we also have something that many companies dealing with repairs and overhauls of mining machines do not have – our own spare parts warehouse, available on site. This significantly shortens repair times. There is no need to wait for weeks for delivery from abroad or interrupt plant operation because a single component is missing.
If the initial diagnostics allow us to determine what has failed, our specialist often visits the Client with the right part already prepared. And if an earlier inspection is required, they return with the part during the next visit, without unnecessary delay. We know how much downtime in a mine costs, and we do our best to help you as quickly as possible.
Do you have a roadheader that needs an overhaul? Contact us – we will prepare an offer for you!
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A new life for your machine – thanks to parts designed by Minostar
Not every repair requires replacing an entire assembly or “half the machine”. Often, it is just one element – a gear wheel in the transmission or a control valve in the pump – that determines whether the roadheader keeps working or stands idle. At our company, we understand this perfectly well, which is why we have developed our own line of spare parts – designed for the specific machine models we work with every day.
Our parts for roadheaders are excellent replacements for original components and, in many cases, offer greater durability and a better fit for real underground operating conditions. These are not the cheapest components made only to fail again after a short time. They are parts selected and designed by people who know what the operation of many popular roadheaders looks like in practice, especially models such as: AM 50, AM 75, AM 105, MR 340, MR 360, MT 360, MT 620, MR 520 and other models used in everyday operation.
Parts for roadheaders designed by us also mean shorter downtime – as mentioned earlier – because most of the parts are available from stock, which significantly reduces repair time. For your company, this means lower losses caused by stopping production at a given heading and a more efficient repair process.
It is worth noting that we also offer these parts for sale as separate products. This means you do not have to commission a comprehensive repair from us if there is no need to do so. You can simply order specific components for your roadheader and carry out the repair on your own, or have it performed by our specialists, who know their trade inside out.
If you need spare parts for your roadheader – check our search tool for the most popular parts or contact us!
Is RESTART worth it? – financially, technically and environmentally
Many Clients ask themselves whether it is worth investing in an old machine. In practice, this is often the most reasonable decision. Even a heavily worn roadheader still represents considerable financial and technical value. A crew that knows the machine and is used to operating it can often work with it very efficiently, which translates into excellent production-related financial results.
With Minostar RESTART, you do not have to bear the cost of purchasing a new machine, which in today’s market can exceed several million PLN. Instead, often at a much lower cost, you can make use of the equipment you already have and adapt your roadheader even more closely to the needs of your mine.
From a technical point of view, RESTART means restoring the machine to full working order, taking into account current safety standards and real operational needs. A roadheader after overhaul or modernisation receives new documentation, a warranty and a detailed description of the work carried out – all in accordance with applicable regulations.
A worn roadheader does not have to end up as scrap
The environmental aspect is also important. Instead of manufacturing a new machine and generating an additional carbon footprint, RESTART allows existing equipment to be given a second life. It is an excellent example of the circular economy model that the entire European Union is working towards.
Throughout this process, we treat every machine individually. We do not carry out repairs just to “get the job done”; we restore functionality while taking into account the Client’s specific needs and the conditions in which the machine will continue to operate. Minostar RESTART is an investment that pays off – not only in terms of cost, but also in reliability, lead time and the operational safety of such a roadheader after a comprehensive overhaul.
Looking for a machine for your mine? We may have one for you
Not everyone who contacts us about modernisation already owns a roadheader. Often, these are companies that use machines on a rental basis or operate a roadheader as a subcontractor without owning it. It also happens that Clients are only planning to purchase their own machine or expand their machinery fleet. In such situations, we can help as well.
Our company purchases used machines, which then undergo the full repair, modernisation or rebuild process as part of the RESTART programme. Once the work is completed, they are offered for sale as fully operational, ready-to-work units.
Every roadheader we offer is a thoroughly inspected machine, after a detailed technical review and supplied with documentation that clearly indicates what has been replaced, modernised or rebuilt. The Client receives a complete set of information, an operating manual, a parts catalogue and a certificate of conformity, so that the machine can be safely put into operation straight away.
This is a very attractive solution, especially for Clients who want to avoid long lead times, the high cost of new equipment or the uncertainty associated with the secondary market. If you decide to purchase a machine from our offer, you can be confident both about its technical condition and its origin.
Give your roadheader a RESTART – summary
Every roadheader that has worked for years in demanding conditions will sooner or later require an overhaul. Instead of writing it off and starting from scratch, it is worth considering RESTART – a solution that allows you to regain performance, efficiency and safety without excessive costs and without losing confidence in the structure you already know.
At our company, we do not promise the impossible. We simply do our job and care about partnership-based relationships with our Clients. You can call us, send photos or ask a question. We will check what can be done with your roadheader and propose specific solutions. We adapt the scope of work to real needs, not to a fixed template set by the manufacturer.
We adapt the scope of work to real needs, not to a fixed template set by the manufacturer. This allows you to save both time and a significant amount of money while maintaining the same quality as with the original manufacturer. Contact us – we will be happy to help!
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