Understanding KiwiRail’s Challenge

KiwiRail required a conveyor solution that could:

• Efficiently remove large volumes of ballast material
• Operate reliably inside a confined, long-distance rail tunnel
• Be fully mobile along the rail network
• Work independently with onboard power
• Provide operators with complete control of the system
• Meet strict rail safety and durability standards

This wasn’t a standard job — it needed a robust, self-contained conveyor system capable of performing in one of New Zealand’s longest and most challenging tunnels.

A Solution Built for the Rimutaka Tunnel

The custom system was specifically built to support KiwiRail’s project inside the Rimutaka Tunnel, a critical 8.93-kilometre rail tunnel running between the Wairarapa and the Hutt Valley.
The conveyors were used to remove ballast material the entire length of the tunnel, providing a safe and efficient way to transport excavated material out of the confined space.

Operating in such an environment demanded reliability, autonomy, and precise control — all of which NZ Conveyors delivered.

Our Custom Conveyor Design

Dual Conveyors Mounted on a Rail Wagon

NZ Conveyors engineered two heavy-duty conveyors mounted directly onto a rail wagon, allowing the system to travel through the 8.93 km tunnel with ease. This mobility gave KiwiRail the ability to position and reposition the equipment exactly where needed throughout the project.

Large Onboard Loading Hopper

A large, purpose-built hopper provided controlled, high-volume loading of ballast material, ensuring smooth transfer onto the conveyors during tunnel excavation.

Self-Sufficient Power System

A generator was integrated into the wagon, making the entire operation fully self-powered — crucial for continuous operation deep within the tunnel where external power is unavailable.

Integrated Lighting & Full Control Interface

NZ Conveyors installed a complete lighting system for safe operation inside the tunnel and a centralised control system giving KiwiRail total control over conveyor speed, start/stop functions, and monitoring.
This setup created seamless, coordinated operation throughout the demanding Rimutaka Tunnel project.

Built for Durability. Designed for Rail Environments.

From structural components to electrical systems, every element was engineered for rugged performance and low maintenance.
Before deployment, the full system was tested, commissioned, and optimised to ensure flawless operation in real-world conditions — especially important given the tunnel’s length and limited accessibility.

Proudly Supporting KiwiRail’s Mission

NZ Conveyors is proud to support KiwiRail in maintaining and upgrading key rail infrastructure across Aotearoa.
This mobile, self-contained conveyor and hopper system delivered a reliable, efficient solution for removing ballast throughout one of the country’s most significant rail tunnels.

Talk to Us About Your Conveyor Project

Whether your project is in rail, tunnelling, construction, mining, or logistics, NZ Conveyors can design and build a system that meets your exact requirements

Get in touch today to discuss your next conveyor solution.

When Shade Systems NZ began work on an Auckland shade sail project, they needed an efficient way to manage excavation spoil on a site with tight access and strict turf protection requirements. NZ Conveyors was brought in to provide a safe, practical, and time-saving solution.

The Project

Remuera Bowling Club in Auckland was upgrading its facilities by installing a large all-weather shade sail. The structure required 20 deep pile footings — each needing significant excavation and careful spoil removal.

Shade Systems NZ designed and managed the build, ensuring a professional finish and minimal disruption to the club.

The Challenge

The bowling green’s limited space and delicate turf made spoil removal especially difficult. Heavy machinery or foot traffic across the greens was prohibited to prevent any surface damage.

Using wheelbarrows to move spoil around the perimeter would have required weeks of labour, delaying the project and adding unnecessary cost.

The Solution

NZ Conveyors supplied and installed a series of Porta-Veyor® portable conveyors — lightweight, modular systems ideal for restricted access worksites. To protect the surface, plywood and PVC sheeting were laid across the greens, with the conveyors positioned directly on top.

The conveyors transported spoil quickly and efficiently across the shortest route — directly over the protected greens — without any risk of damage.

The Result

The project was completed ahead of schedule and without a single mark on the turf.

✅ Spoil removal completed in just one week
✅ No turf or site damage
✅ Reduced manual labour and faster turnaround
✅ Happy contractor and an even happier client

About NZ Conveyors

NZ Conveyors provides portable and modular conveyor systems for hire and sale across New Zealand. From tight access residential sites to large industrial projects, our conveyors help businesses move materials faster, safer, and more efficiently.