Any complex operation in the mining industry will know the importance of metallurgical accounting. For operations managers and superintendents, accurate tracking of material flow, inventory, and processing efficiency isn’t just a regulatory requirement—it’s key to optimising performance and maintaining profitability.
However, many teams still rely on tools such as Excel to manage their metallurgical accounting tasks. While Excel is flexible and familiar, it has significant limitations that can compromise the accuracy and reliability of the data.
So what are the most common issues with relying on Excel, and what is the solution?
Six problems with Excel
1. Data entry, calculations and reporting often occur on the same sheet
In metallurgical accounting, different processes generate a range of complex datasets including intermingled inputs and calculations that need to be formatted for presentation.
When all these operations are completed on the same Excel sheet, the risk of error increases and increases the complexity of checking entries and data.
A single incorrect cell entry can impact linked calculations, creating significant inaccuracies in reports.
2. Excel storage of data takes up a lot of memory
Metallurgical processes generate large amounts of data daily, especially with real-time monitoring systems.
Storing this information in Excel can significantly slow down performance.
For instance, a plant tracking hourly production data over a year would generate over 8,000 rows per metric, creating files that strain both local systems and cloud storage.
3. Large spreadsheets become unstable
When spreadsheets grow, they tend to crash.
Superintendents often report instability when working with files exceeding 100 MB, especially those packed with formulas, graphs, and pivot tables.
This not only disrupts workflows but also risks the loss of critical data during unscheduled crashes.
4. Memory usage increases with data visualisation
Visualisation tools such as charts and conditional formatting are essential for identifying trends. However, adding these elements in Excel causes memory usage to spike. Tracking daily ore grades using dynamic charts might turn a manageable 20 MB file into a 150 MB file.
5. Data is broken into manageable chunks rather than being continuous
Operations often split large datasets into multiple files to keep things running smoothly.
This fragmentation makes it difficult to analyse data holistically.
For instance, tracking monthly recovery trends might involve manually merging 12 separate spreadsheets.
This not only means workers spend more time merging files, but it increases the risk of errors.
6. Formulas can be incorrectly edited, causing a flow-on effect
One of Excel’s greatest strengths—editable formulas—can also be its weakness.
A minor error, such as deleting a reference cell in a recovery rate formula, can result in an entire month’s production analysis being incorrect.
These mistakes often go unnoticed until they have a significant impact.
Solutions
Mipac’s MPA software suite of digital applications directly addresses the limitations of Excel while catering specifically to the needs of metallurgical accounting.
These tools are designed to handle the complexities of mineral processing, providing greater accuracy, reliability, and operational insight.
Here’s how some of the applications outshine Excel:
Golden State:
While Excel can track basic metrics, it struggles with live data integration and complex process monitoring.
Golden State excels by visualising key performance drivers in real-time, identifying deviations from control limits, and pinpointing inefficiencies (“bad actors”) instantly.
This ensures production deviations are addressed proactively—something Excel cannot automate or reliably track without manual intervention.
Digital TARP:
Metallurgical operations rely on quick, structured responses to deviations.
Digital TARP provides clear, predefined corrective action plans for anticipated events, reducing reliance on manually updated Excel sheets.
It uses historical data to improve decision-making over time, an advantage Excel lacks due to its fragmented and static nature.
Production Reporting:
Unlike Excel, where reports often require tedious manual updates and data consolidation, Production Reporting integrates multiple data sources into dynamic, pre-populated reports.
This eliminates errors caused by manual data entry and ensures production KPIs like budget vs actual are accurate, up-to-date, and easy to analyse over adjustable timeframes.
The MPA suite overcomes Excel’s inherent limitations in metallurgical accounting by automating data collection, reducing manual errors and providing actionable insights in real-time.
Excel’s fragmented approach to data management and visualisation makes it unsuitable for the high-stakes environment of metallurgical operations, where delays and inaccuracies can impact both compliance and profitability.
MPA’s seamless integration, robust data handling, and industry-specific capabilities ensure that operations managers and superintendents can make informed decisions with confidence.
Read more about Mipac's products
As technology continues to evolve at an unprecedented pace, mining companies are increasingly starting to adopt to innovative software solutions to enhance …
In the mineral processing industry, where every tonne counts and operational efficiency determines profitability, Operational Equipment Effectiveness (OEE) emerges as a key metric.
Process stability is a key driver to maximising production, enhancing safety and reducing waste. In this article we are going to provide some background and insight into how you can achieve operational excellence by managing variability to optimise production.
