Senior Crushing Plant Operator / Senior Operator – Primary Crushing

Job Purpose

To lead and operate the primary crushing section safely and efficiently, ensuring continuous ore flow, optimal crusher performance, and compliance with safety and metallurgical requirements. The Senior Plant Operator provides operational leadership, assists with troubleshooting, mentors junior operators, and ensures reliable plant performance to meet zinc production targets.

Key Responsibilities

Crushing Plant Operation

Operate and monitor all equipment in the crushing section, including:

• Gyratory crusher
• ROM bin and dump pocket
• Apron feeders
• Scalping screens
• Primary conveyors and chutes
• Maintain consistent feed rates and product size to support downstream milling.

Operational Leadership

Act as the lead operator on shift, coordinating duties of:

• Control room operators
• Field operators
• ROM/apron feeder operators
• Provide hands-on guidance and training to junior operators.
• Stand in for the Crushing Supervisor when required.

Process Monitoring & Optimisation

• Monitor and adjust operational parameters based on ore type, hardness, and moisture.
• Identify potential bottlenecks and take corrective actions to maintain throughput targets.
• Report metallurgical or process deviations to the Supervisor or plant metallurgist.

Safety & Compliance

Enforce safety standards and ensure compliance with:

• Mine Health & Safety Act (MHSA)
• Lock-out/Tag-out procedures
• Permit-to-work systems
• Machine guarding and safe dumping practices
• Conduct safety checks and participate in toolbox talks.

Plant Inspections & Fault Detection

Conduct routine inspections of:

• Crusher chamber, mantle, concaves
• Feeder pans, chains, and rollers
• Belt tracking, spillage, and chutes
• Lubrication and hydraulic systems
• Detect abnormal noises, vibrations, or operational changes and escalate promptly.

Breakdown Support & Troubleshooting

• Provide first-response support during plant trips or stoppages.
• Assist maintenance teams with:
• Clearing blockages
• Isolations and safe restart procedures
• Identifying root causes of recurring faults
• Coordinate with the control room during plant restarts.

Shift Reporting & Documentation

• Complete shift logs, downtime reports, inspection sheets, and handover notes.
• Record deviations, corrective actions, and production-related issues.
• Communicate key shift events to the oncoming team and supervisors.

Required Skills & Competencies

Technical Competencies

Strong understanding of:

• Gyratory crusher operation
• ROM bin/apron feeder systems
• Conveyor and screening equipment
• Ore handling and fragmentation principles
• Ability to interpret plant trends, logs, and alarms.
• Basic troubleshooting capability (mechanical/electrical awareness).

Behavioural Competencies

• Strong leadership presence and decision-making ability.
• High safety awareness and commitment to compliance.
• Clear communication and radio discipline.
• Ability to work under pressure during breakdowns.
• Strong teamwork and mentoring ability.

Qualifications & Experience

Minimum Requirements

• Grade 12 (Matric) or equivalent.
• 4–7 years' experience in a crushing plant or mineral processing environment.
• Proven experience on primary crushers (especially gyratory units).
• Ability to work shifts, overtime, and callouts.

Preferred

• NQF Level 2–4 in Mineral Processing / Plant Operations.
• Experience in zinc, lead, or base metal operations.
• Supervisory or leadership training.
• Understanding of crushing control systems (SCADA/DCS).

Physical & Work Environment Conditions

• Work in dusty, noisy, and high-vibration environments.
• Climbing of structures and regular field inspections required.
• Must be physically fit and able to respond to breakdowns promptly.
• Shift work, nights, weekends, and overtime required.

Key Performance Indicators (KPIs)

• Crushing plant throughput and uptime.
• Product size consistency.
• Safety compliance and zero incidents.
• Quality of shift reporting and communication.
• Effective mentoring of junior operators.
• Housekeeping and operational discipline in crushing areas.