Control systems built for the field, not adapted to it.
DCS, SCADA, and industrial analytics for mining operations, mineral processing plants, and metals manufacturing. Engineered for the dust, vibration, scale, and uptime demands of heavy industry.
Three things bleeding tons and dollars on the floor.
Standalone process islands
Crushing, grinding, flotation, and thickening each run on their own PLC and HMI with no plant-wide view. Control room operators can't see the full circuit. Production data gets logged on paper and reconciled the next morning.
Manual sequencing eats throughput
Operators start each conveyor section by hand, watch belt speeds visually, and adjust feed rates from experience. Misloads, tracking issues, and uncoordinated starts cause stoppages that compound across miles of belt.
Energy that gets ignored
Mill motors run full speed continuously. Pumps and fans operate without VFD control. Power is the second-largest line item on the operating cost sheet, and nothing on the floor is tuned to reduce it.
Three systems we build for mining and metals operations.
Built for harsh environments,
and production pressure.
Outcomes from recent mining and metals deployments. Conveyor automation, plant-wide SCADA, and VFD mill retrofits. Specific projects scoped on request.
Got a process circuit that should be running itself?
Straight answers.
Yes. Mining environments destroy equipment that wasn't designed for them — dust, vibration, temperature extremes, and moisture. We specify enclosures, cabling, and hardware rated for the actual conditions, and we design control architectures for the scale and distributed nature of mining operations.
Yes. Interlocked PLC control for long conveyor systems, belt scale feedback for automated feed rate adjustment, belt tracking monitoring with automated correction, and centralized SCADA for coordinated starts, stops, and troubleshooting. Operator staffing for conveyor monitoring typically decreases after deployment and conveyor availability increases.
Yes. Large motor control for crushers, mills, conveyors, pumps, and fans — including medium voltage drive integration. VFD applications for energy optimization and soft starting of high-inertia loads. Motor protection coordination, automated load sharing, and sequencing for parallel equipment.
Centralized SCADA on Ignition, FactoryTalk, or WinCC that provides plant-wide and site-wide visibility. Process overviews that show status at a glance, detailed screens for troubleshooting, and alarm management designed for the high-alarm environments typical of mining. Historian integration for process trending and reporting.
IEC 62061 and relevant mining safety standards. Emergency stop systems, conveyor pull-cord monitoring, bin level safety interlocks, and gas detection system integration. Safety PLC programming on GuardLogix and Siemens F-PLCs. Safeguarding for automated equipment in proximity to personnel.
Yes. For mining operations that have outgrown their original monitoring capacity, we add data collection to existing equipment for OEE tracking and process optimization — whether that's direct PLC communication, I/O monitoring modules, or edge gateways that normalize data into a unified SCADA platform.
Ready to talk about your operation?
Whether it's a conveyor system, a processing plant upgrade, or a full-site SCADA deployment — tell us about the project.