Yancoal’s Electric Drive Journey at MTW

At Mount Thorley Warkworth (MTW) in the Hunter Valley, every investment is evaluated against four key priorities: productivity, reliability, sustainability and the long-term wellbeing of the communities surrounding the operation. 

As the mining industry continues to navigate the transition towards lower-emission operations, sites are looking for practical ways to improve efficiency while supporting their sustainability goals. For Yancoal, investing in a fleet of 18 Cat 794 AC Electric Drive Mining Trucks represented an opportunity to do exactly that.  

The results are already delivering tangible benefits, with fuel consumption improving by approximately 10 percent, alongside gains in productivity and operational performance.

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For MTW General Manager Cris Shadbolt, the decision wasn’t simply about introducing new equipment – it was about building a more resilient, efficient and sustainable operation for the future.  

“Sustainability is extremely important in Yancoal’s future plans…and our social license to operate is critical.”  

Supporting a More Sustainable Future 

When Yancoal began evaluating its next haul truck fleet, the focus wasn’t solely on production. The team was looking for a solution that could integrate seamlessly with its existing fleet, while delivering measurable improvements in fuel efficiency, productivity and long-term performance.  

“Our investment in the 794s came through a rigorous process of looking at what’s going to be the best fit for us here under our Tier 1 excavator fleet,” Cris explained.   

The Cat 794 AC’s electric drive technology quickly emerged as a strong fit, combining the payload capacity and reliability required for a large-scale mining operation with the potential to significantly improve fuel efficiency.   

For a site producing around 18 million tonnes annually, even modest improvements in efficiency can create long-term benefits. Lower fuel consumption not only reduces operating costs but also supports Yancoal’s broader environmental objectives through lower emissions and more efficient energy use.

Electric drive delivers operational gains 

Since introducing the 794 AC fleet, the benefits have extended well beyond fuel savings.  

Matched with the site’s existing shovel and excavator fleet, the trucks have integrated seamlessly into daily operations, helping maximise payloads, reduce passes and improve haul cycle efficiency.  

According to Yancoal MTW Maintenance Manager Warwick Gloster, operator feedback has also been exceptionally positive.  

“The 794s have performed outstanding…operators really like them,” he said.  

The trucks’ responsiveness, improved visibility and ease of operation have contributed to strong adoption across crews, while their performance on ramps and through haul cycles has seen a boost in productivity.  

“The 794s are quick to spot, quick to take off, and their ramp speeds have been excellent with optimal payloads,” Cris explained.  

Cris added the fleet has also demonstrated reliability in demanding conditions. 

“The 794s are one of the last trucks to park up in wet weather and one of the first to get going again.” 

For a 24/7 operation, that resilience translates into greater uptime, improved productivity and more consistent operational performance.  

Turning Efficiency into measurable outcomes 

While the full benefits of electric drive technology continue to evolve over time, Yancoal is already seeing encouraging results.  

“What we’ve seen is around 10 percent fuel burn improvement in these new 794s,” Warwick noted. 

For the MTW team, those gains represent more than improved operating efficiency.   

Reduced fuel consumption lowers operating costs while contributing to lower greenhouse gas emissions, supporting Yancoal’s long-term environmental commitments. Combined with onboard technology and fuel management systems, the site now has greater visibility into fleet performance, enabling more informed decision-making and continuous improvement.  

It’s an investment that is delivering value today while helping prepare the operation for the next generation of mining technologies.  

Balancing productivity with community expectations  

At MTW, sustainability extends well beyond reducing emissions. It also means creating safer workplaces, minimising environmental impacts and maintaining the trust of the communities that surround the operation.    

Recent additions, including larger Cat® 789D Water Trucks, have strengthened dust suppression capabilities across the operation.  

“We have some of the tightest restrictions on dust and noise in the world,” Warwick said. 

“We really care about our local community and the impact we’re having on it.” 

For Yancoal, keeping its social license to operate means continuously looking for ways to improve performance while being mindful of its environmental responsibilities.  

The introduction of the electric drive 794 AC fleet forms part of that broader strategy – demonstrating that operational excellence and environmental responsibility can progress hand in hand.

A partnership focused on long-term outcomes  

Delivering change at this scale requires more than equipment alone, with Yancoal working closely with WesTrac and Caterpillar throughout the rollout of the 794 AC fleet, to ensure the fleet met site requirements and delivered expected outcomes.  

According to Cris, good communication has been a key factor in the partnership’s success.  

“Yancoal has an excellent relationship with WesTrac because there’s very open communication,” he said.  

This collaborative approach Cris added, has helped both organisations focus on continuous improvement, performance optimisation and long-term success.  

“Having support on site is imperative, it results in more uptime for us with the 794s.” 

It’s a partnership built on a shared vision – working together to improve today’s operation while helping shape a more sustainable future for mining.  

Looking ahead 

With the 794 AC fleet now operating successfully on site, and additional units already planned, Yancoal sees electric drive technology playing an increasingly important role in its future. 

“We have 16 new Cat 794 AC trucks on site, with another two coming next year,” Cris said.  

For MTW, the fleet represents far more than a haulage upgrade. 

It represents an investment in smarter technology, stronger partnerships and a more sustainable future.  

As the mining industry continues to evolve, Yancoal’s electric drive journey demonstrates what’s possible when innovation, collaboration and a shared commitment to continuous improvement come together. By building better together, Yancoal, WesTrac and Caterpillar are helping create a mining operation that is more productive today and better prepared for tomorrow. 

Frequently Asked Questions

Why did Yancoal choose the Cat 794 AC electric drive mining truck at MTW?

Yancoal selected the Cat 794 AC following a rigorous evaluation process focused on productivity, reliability, sustainability and fleet compatibility. The truck’s electric drive technology, strong payload capability and ability to integrate with MTW’s existing Tier 1 excavator fleet made it the best fit for the operation’s long-term goals.

How much fuel savings has Yancoal achieved with the Cat 794 AC fleet?

Since introducing the Cat 794 AC fleet, Yancoal’s Mount Thorley Warkworth operation has recorded approximately 10 percent lower fuel consumption compared to previous haul truck performance. These fuel savings help reduce operating costs while supporting the site’s emissions reduction and sustainability objectives.

What productivity benefits has the Cat 794 AC delivered at MTW?

According to Yancoal, the Cat 794 AC fleet has improved haul cycle performance, ramp speeds and overall productivity. The trucks work effectively with the site’s shovel and excavator fleet, helping maximise payloads, reduce loading passes and maintain strong performance in demanding mining conditions.

What do operators think of the Cat 794 AC trucks?

Operator feedback at MTW has been overwhelmingly positive. Yancoal reports that operators appreciate the trucks’ responsiveness, visibility and ease of operation. The fleet has been well received across crews and has contributed to strong adoption on site.

How does the Cat 794 AC support mining sustainability goals?

The Cat 794 AC’s electric drive technology helps improve fuel efficiency and reduce fuel burn, lowering greenhouse gas emissions associated with haulage operations. At Yancoal’s MTW operation, the fleet forms part of a broader strategy to improve environmental performance, support responsible mining practices and strengthen the site’s long-term sustainability outcomes.

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