Chutes And Transfer Stations: Seeing Inside the Chute

How 3D Scanning Transforms Transfer Station

In mining and processing plants, chutes and transfer stations are the unseen workhorses that keep material moving from one conveyor to the next. When they work well, everything flows smoothly. When they don’t, production stops, crews scramble, and costs escalate. The challenge is that these critical assets are often difficult to inspect, tucked away in tight spaces and surrounded by structural steel, services, and walkways. Over time, liners wear down, plates deform, and small modifications accumulate, changing the way material behaves inside the chute. By the time blockages or spillage appear, the problem has already disrupted operations.

This is where 3D scanning is changing the way plants approach design and maintenance. Instead of relying on outdated drawings or rough tape measurements, engineers can now capture a millimetre-accurate digital record of the entire transfer station in a single scan session. High-resolution laser data shows the exact internal profile of the chute as it exists today, including wear patterns, deformations, and even accumulated material. Because the surrounding conveyors, walkways, and piping are scanned at the same time, engineers get the full picture of the installation.

Once the scan is complete, the point cloud becomes a living model of the asset. Designers can drop it straight into their CAD environment and see, in detail, where clearances are tight and where modifications have created potential pinch points. From here, digital models of new chutes or liners can be overlaid to confirm that they will fit perfectly on the first attempt, avoiding rework and expensive shutdown delays. Engineers can even run flow simulations directly against the scanned geometry to test different designs and predict how changes will affect throughput and wear.

The result is a smoother, faster upgrade process. Instead of surprises during installation, teams know exactly what they’re working with. Instead of estimating liner wear, they can plan replacement intervals with confidence. Instead of rushing crews back for extra measurements, they have all the data they need from day one.

Chutes and transfer stations may seem simple, but they play a huge role in plant performance and downtime risk. By using 3D scanning as the foundation for chute design and maintenance, mining and processing operations can move from reactive fixes to proactive improvement. The difference is not just more accurate data — it is a completely new level of confidence in the way material handling projects are delivered.

At Hamilton by Design, we help mining and processing clients capture that confidence. Our team uses high-resolution scanning to document existing infrastructure, build accurate models, and work alongside your engineers to deliver solutions that fit right the first time. If your next shutdown is approaching and you need reliable data to plan a chute upgrade, we’re ready to help turn your plant into a safer, more efficient operation — one scan at a time.