When KiwiRail needed a reliable, efficient way to handle material movement for one of their most demanding rail projects, they turned to NZ Conveyors – and for good reason. With decades of experience designing and building conveyor solutions across New Zealand, our team was ready to deliver a system tailored precisely to their environment, workflow, and safety requirements.
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.