Control systems built for
the hardest environments on earth.
Mining and metals operations run in environments that destroy equipment designed for factory floors — extreme temperatures, corrosive dust, vibration, moisture, and remote locations where a technician is hours away. The control systems running crushers, conveyors, mills, and processing plants need to be robust enough to survive these conditions and reliable enough that operations don't stop when something fails.
We design and deploy control systems as a mining and minerals system integrator — for mining operations, mineral processing plants, metals manufacturing, and aggregate production. PLC programming, SCADA, motor control, and system integration engineered for the scale, harshness, and operational demands of heavy industry.
Panels and networks that fail the moment real-world dust, vibration, and moisture hit them.
- —Standalone HMIs per process area, no plant view
- —Manual conveyor starts and feed rate adjustments
- —Mill motors running full speed continuously
Plant-wide SCADA, automated conveyors, and VFD-optimized motors that actually survive the environment.
- Unified SCADA across crushing, grinding, flotation
- Self-coordinating overland conveyor systems
- VFD mill speed control tied to process load
Eight capabilities,
built for heavy industry.
Structured PLC logic on Allen-Bradley and Siemens platforms for mining and metals applications. Crusher sequencing, conveyor interlocking, mill control, flotation circuit automation, thickener level control, and furnace process logic. Material handling systems with belt scale integration, bin level monitoring, and automated routing. Process control loops for temperature, pressure, flow, and chemical dosing in mineral processing circuits.
View serviceReal projects,
measurable results.
A conveyor system that runs itself.
A mining operation was running a 3-mile overland conveyor system with manual start/stop sequencing — operators started each conveyor section individually, monitored belt speeds visually, and manually adjusted feed rates based on experience. Misloads, belt tracking issues, and uncoordinated starts caused frequent stoppages. We automated the entire conveyor system with interlocked PLC control, belt scale feedback for automated feed rate adjustment, belt tracking monitoring with automated correction, and a centralized SCADA interface. The system starts and stops in coordinated sequence, adjusts to production demand automatically, and alerts operators to issues before they become failures. Conveyor availability increased by 15%, and operator staffing requirements for the conveyor system decreased.
Process visibility across the plant.
A mineral processing plant had PLC control on individual process areas — crushing, grinding, flotation, and thickening — but no unified SCADA system. Each area had its own standalone HMI with no connection to the others. Control room operators couldn't see the complete process flow, and production data was recorded manually. We deployed a plant-wide SCADA system on Ignition that integrates with all existing PLCs, providing a unified view of the entire processing circuit from a centralized control room. Historians capture process data at configurable intervals. Dashboards show throughput, recovery rates, and reagent consumption in real time. The operations team now makes process adjustments based on data instead of gut feel.
Motor control that saves money.
A metals processing facility was running six large mill motors at full speed continuously, with no speed control and no energy optimization. Power consumption was the facility's second-largest operating cost. We retrofitted VFDs on the mill motors with PLC-based speed control optimized for process load. The control logic adjusts mill speed based on feed rate and product quality indicators, maintaining process performance while minimizing energy consumption. Annual energy cost for the mill circuit decreased by 25%.
The stack we deploy
in mining and metals.
Allen-Bradley ControlLogix & CompactLogix, Siemens S7-1500 & S7-1200
Ignition, FactoryTalk, Siemens WinCC, AVEVA
Allen-Bradley GuardLogix, Siemens F-PLCs, mining-specific safety standards
Allen-Bradley PowerFlex, Siemens Sinamics, ABB ACS — including medium voltage applications
EtherNet/IP, PROFINET, fiber optic, industrial wireless, IT/OT segmentation
Belt scales, level sensors, flow meters, vibration monitors, analytical instruments
Built for the field,
not adapted to it.
We build for the environment.
Mining environments destroy equipment that wasn't designed for them. We specify enclosures, cabling, and hardware rated for the actual conditions — dust, vibration, temperature extremes, and moisture. Control systems that work in the spec sheet but fail in the field aren't systems we build.
We understand throughput.
Mining is a volume business. Every hour of downtime is tons of material not processed and revenue not generated. We design control systems that maximize availability, minimize unplanned stops, and give operations teams the data to optimize throughput.
We handle the scale.
Mining operations are big — miles of conveyors, hundreds of motors, thousands of instruments. We design control and SCADA architectures that scale to the size of the operation without becoming unmanageable.
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.