In a significant step forward for operational excellence, Kilimanjaro Group has completed the full deployment of next-generation emulsion blasting systems across all major mining sites, including our primary operations in Geita, Kahama, and Musoma.

This initiative represents months of coordinated work between our technical team, site operators, and our strategic partner Dyno Nobel. The new systems deliver measurable improvements across every key performance metric — from fragmentation quality and blast efficiency to safety margins and cost per tonne.

What's New in the Technology

The new emulsion formulation offers several important advances over our previous system. Each of these translates directly into operational benefits on site:

  • Higher Velocity of Detonation (VOD) — More consistent energy release across varying rock conditions
  • Superior water resistance — Reliable performance even in flooded boreholes and heavy rainfall
  • Optimized density range — Better control over energy distribution within the blast column
  • Reduced handling risk — Non-nitroglycerin formulation for safer storage and transport

These improvements compound. The higher VOD combined with better density control allows our blasting engineers to fine-tune the energy input on a per-hole basis — reducing over-blasting in soft zones while ensuring adequate breakage in harder rock.

"We've been testing this system for over six months. The results speak for themselves — fragmentation has improved by 23% and our secondary blasting needs have dropped dramatically."
— Senior Blasting Engineer, Kahama Operations

The Rollout Process

The rollout was not a simple product swap. Each site underwent a phased transition with extensive testing and validation before full deployment.

Our team completed over 200 supervised test blasts across varying geologies during the validation phase. Fragmentation analysis was performed using drone-based photogrammetry and image analysis software to objectively quantify improvements.

Safety was the priority throughout. The transition was completed with zero safety incidents — a testament to the rigor of our training programs and the discipline of our operational teams.

Key Results at a Glance

  • 23% improvement in fragmentation consistency
  • Reduced secondary blasting requirements across all sites
  • Faster loading and hauling cycles with fewer oversized rocks
  • Lower wear rates on downstream crushing equipment
  • Consistent performance across wet and dry conditions

What This Means for Our Customers

For mining operations that rely on Kilimanjaro Group for their blasting solutions, the benefits are tangible:

Lower total cost per tonne. Better fragmentation translates to lower drilling costs, lower explosives consumption, and reduced downstream processing costs.

Predictable results. The consistency of the new systems means site teams can plan more accurately — less variation between planned and actual outcomes.

Improved safety. Safer handling and more reliable detonation reduce the risk of misfires and other safety concerns.

Environmental benefits. More efficient blasting means less ground vibration, less flyrock, and lower overall carbon footprint per tonne moved.

Looking Ahead

The system is now fully operational across Geita, Kahama, and Musoma. Through 2027, we'll continue to expand deployment to new sites, with ongoing analysis to further optimize performance across different rock conditions.

Our technical team is also working closely with Dyno Nobel on the next iteration of the technology — aiming for even greater efficiency gains and further reductions in environmental impact.

If you'd like to know more about how these advances could benefit your operation, please get in touch with our technical team. We're always happy to discuss the specific needs of your site.