Thunder Bay Terminals reduces downtime using custom Metso roll solution

For years, Thunder Bay Terminals relied on Stephens-Adamson conveyor rolls and idlers - and for good reason. Some of the original rolls installed in 1978 are still operating there today, setting a high benchmark for reliability. When that design was no longer available, the site trialed several alternative manufacturers, but experienced premature failures or consistency issues. Looking for a more reliable and long-term solution, Thunder Bay Terminals partnered with Metso to develop a tailored replacement - together. 

“Some of the rollers that we’ve had in the past, we’d be lucky to get two years out of them,” says Colin Carr, General Superintendent at Thunder Bay Terminals. “Even if a shutdown during vessel-loading took only one hour, it’s downtime and costs that we shouldn’t have.” 

Beyond the price of replacing failed rolls, which inevitably increased maintenance costs and safety risks, the issue was also how the stoppage was impacting the entire operation. 

“The site can’t afford too many roll breakdowns because this can destroy or damage a conveyor belt, and forces them to stop the system mid-loading,” says Jordan Bloom, Business Development Manager, Material Transportation at Metso Canada. “This costs a lot of time, and time costs a lot of money. Every hour is critical.” 

The hidden cost of unreliable rolls: Risks to safety and productivity

As a dry bulk handling facility, Thunder Bay Terminals depends on conveyors to keep the operation moving efficiently. A single roll failure can trigger a chain reaction: stopped conveyors, delayed vessel loading, unplanned maintenance and lost productivity. For a site where nearly everything moves by conveyor, reliability is essential to keep operations running safely and efficiently.   

“Frequent roll changeouts also create additional safety risks for workers. When roll failures and changeouts happen, it puts personnel in harm’s way,” says Jordan. “A lot of times, you’re lifting long and heavy rolls, which creates a lifting hazard. You also might be elevated over top of other equipment or even on the ground over stackers or certain conveyors. By having a roll that lasts longer, it reduces the exposure for maintenance personnel since they don’t need to replace them as often.”  

Thunder Bay Terminals needed a solution that would last longer, reduce the frequency of maintenance interventions and limit unnecessary safety exposure—all without compromising the reliability needed to keep vessel-loading moving. 
 

Engineered for operational demands  

Developing the solution became a collaborative engineering effort for Metso, as it focused on Thunder Bay Terminals' operating conditions, performance expectations and practical site challenges. Rather than supplying an off-the-shelf replacement, Metso worked closely with the site to understand why the previous rolls were failing and what the new design needed to withstand.  

“We took their problem and we analyzed it,” says Jordan. “We looked at the lifespan of their current idlers and rolls, and where they wanted to get to. We took that information and designed them a roll that was going to last to maximize their efficiency and uptime.” 

The resulting design featured a thicker shell, a larger shaft diameter, higher-quality sealing and larger bearings. The increased shaft diameter was intended to reduce angular deflection of the bearings, while the overall design was engineered specifically to increase durability and service life under Thunder Bay Terminals' operating conditions.

Maximizing lifespan, minimizing downtime 

Previously, roll life could be measured in weeks or months. Now, four years after installation, the impact is clear: the custom-engineered Metso rolls continue to operate without a single failure.

A safer way to keep material moving 

By reducing the frequency of roll replacements, Thunder Bay Terminals has significantly reduced unplanned maintenance interventions. Replacing rolls can involve manual lifting, working around heavy equipment and, in some cases, performing maintenance at height. With an extended roll life, the site has reduced worker exposure to these tasks whilst improving maintenance, production and cost efficiency—all at the same time. 

Working together for lasting results  

“Our experience working with Metso on this project has been excellent,” says Colin. “This has exceeded a standard purchase and was a real joint effort. They have provided everything we’ve needed in a timely fashion and at a fair price. Metso went to bat for us, so it was seamless.” 

With a comprehensive portfolio of port solutions and bulk material handling technologies – such as conveyors, stacker reclaimers, ship loaders and unloaders, railcar dumper cars and smart automation solutions – Metso can support customers across the full material handling process, helping them build safer and more reliable operations for the long term. 

This project demonstrates how close collaboration, customization and technical know-how can help bulk material handling operations improve reliability, enhance safety and maximize long-term profitability – further highlighting what it means to work with Metso as a partner for positive change.