Mineral Processing Automation

Mineral Processing Automation

Enhancing Efficiency across your Plant

INDUSTRIAL AUTOMATION PROCESS OPTIMISATION

Mineral process automation transforms how mining operations optimize efficiency, control costs, and maximise recovery rates. Every plant, from crushing to final product handling, faces unique challenges that demand smarter solutions. Without advanced process control, inefficiencies lead to excessive energy use, unplanned downtime, and lost material.

Mipac provides comprehensive optimization strategies tailored to the specific needs of mineral processing plants. With decades of experience and a deep understanding of automation technologies, we integrate advanced control systems like Siemens’ SIMATIC PCS 7, Yokogawa’s CENTUM VP, and Rockwell Automation’s FactoryTalk to drive measurable improvements.

Whether enhancing grinding efficiency, stabilizing the performance of beneficiation circuits, or automating smelting and refining in metal conversion circuits, our solutions are designed to increase throughput, improve sustainability, and ensure long-term plant reliability.

This page explores how Mipac’s expertise can optimize your mineral processing automation, linking to real-world projects that demonstrate the value of intelligent process control.

Crushing Circuit Optimization

Crushers set the stage for downstream efficiency. Mipac’s automation adjusts gap settings and feed rates in real-time to reduce blockages, stabilise throughput, and extend component life.
 
Efficient size reduction is the cornerstone of effective mineral processing. Our advanced control systems stabilize crusher operations, improving throughput and reducing energy consumption. By integrating real-time data analytics, we can drive towards optimal crusher performance, minimizing wear and operational costs.
 
How we do it:
Crushing Circuit

Explore our Crusher Control Project to see how we’ve enhanced crushing efficiency for our clients.

Grinding Process Enhancement

Unstable mill loads lead to energy waste and inconsistent product particle size. Our systems automate mill speed, water flow, and feed rates to maintain your optimal grinding conditions.
Grinding circuits often operate below capacity due to suboptimal control strategies. Mipac’s mineral processing automation solutions, including implementing the latest control system technology, provide precise control over grinding parameters. This results in energy savings, increased throughput, and extended equipment lifespan.
How we do it:
Grinding Process

Explore our Grinding Optimisation Case Study to see how we’ve enhanced crushing efficiency for our clients.

Flotation Process Control

Manual flotation adjustments can’t keep pace with ore variability. Mipac automates air flow, reagent dosing, and froth depth to improve concentrate grades and reduce reagent waste.
Achieving maximum metal recovery requires precise flotation control. Our expertise in advanced process control, utilising tools from leading providers Siemens, Yokogawa and Rockwell Automation, allows for real-time adjustments to flotation inputs, ensuring improved recovery rates and concentrate grades.
How we do it
Flotation Control

Read about our Flotation Control Success Story to learn more..

Leaching and Solvent Extraction Optimization

Manual parameter adjustments will not react as quickly as variable changes in leaching and solvent extraction circuits leading to recovery losses. Mipac automates leaching parameters to stabilize extraction rates and reduce chemical waste, while maintaining recovery targets. 
 
Optimizing leaching and solvent extraction processes is vital for efficient metal recovery. Mipac’s control solutions monitor and adjust critical parameters, enhancing reaction kinetics and extraction efficiency. Our approach reduces reagent consumption and operational costs.
How we do it
  • Optimize pH for improved leach kinetics.
  • Reduce chemical usage while maintaining extraction rates.
  • Automate solvent extraction circuits for greater efficiency.
Flotation Control

Download your free copy of our Mineral Processing Opeations Playbook

DOWNLOAD
Mipac Operations Playbook

Dewatering and Tailings Management

Water scarcity and tightening regulations demand smarter tailings solutions. Mipac’s automation optimises thickener performance and tailings stability with automation that maximizes water recovery and compliance.

Effective dewatering is essential for water recovery and tailings management. Our automation strategies optimize equipment such as thickeners and filters, ensuring maximum water recovery and safe tailings disposal. This approach conserves water and enhances environmental compliance.

How we do it
  • Maximize water recovery to reduce freshwater dependency.
  • Improve thickener underflow control to stabilize leach feed or tailings disposal.
  • Reduce environmental impact with smarter tailings management.
  • Automate dewatering processes for consistent performance.
Dewatering and Tailings

Learn from the Tailings Circuit Performance Improvement project at this copper operation

Smelting and Refining Excellence

Furnace instability impacts yield and energy costs. Mipac enhances smelting control with real-time temperature monitoring, automated slag management, and emissions tracking—balancing metal purity with operational efficiency

In smelting and refining, process stability directly impacts metal purity and energy consumption. Mipac’s mineral processing automation solutions include upgrades to systems from leading industrial OT providers and enhanced furnace control and temperature regulation. This results in higher yield, reduced energy usage, and extended equipment life.

How we do it
  • Improve furnace temperature control for enhanced efficiency.
  • Reduce slag losses through precise feed monitoring.
  • Automate gas and emissions control for compliance.
  • Extend refractory life with optimized heat management.
Smelter

View our Smelter Control System Upgrade to see our work in action.

Final Product Handling

Bottlenecks in stockpiling, loading, or shipping erode profit margins. Mipac automates material tracking and loading systems to eliminate bottlenecks and reduce demurrage costs.

Streamlined product handling ensures that your final product reaches the market efficiently. Our automation solutions optimise material tracking, stockpile management, and loading systems. This reduces bottlenecks, improves dispatch accuracy, and lowers logistics costs.
 
How we do it
Train Loadout

Explore our Coal Loadout Optimisation Project for detailed insights.

Let us take the lead

With 3 decades in the industry and a project portfolio covering 100+ sites around the globe, Mipac combines deep technical expertise with a commitment to client success. Our team leverages cutting-edge mineral processing automation technologies, such as Siemens’ SIMATIC PCS 7, Yokogawa’s CENTUM VP, and Rockwell Automation’s FactoryTalk, to deliver tailored solutions that address your unique challenges.


Visit our Projects Page to see how we’ve partnered with clients worldwide to optimise their operations.

Proven processing experience across:

Ready to elevate your plant's performance?

Contact Mipac today to discuss how our comprehensive automation and optimization solutions can transform your mineral processing operations.

For more information, Contact Us or explore Our Services.

Check out our latest automation articles:

The Mining Automation Pyramid

The Mining Automation Pyramid

Digital transformation is reshaping the mining and mineral processing industries, helping operations managers tackle challenges like improving efficiency, reducing downtime,…

Read more
Copper Processing is in our DNA

Copper Processing is in our DNA

At Mipac, the automation of copper processing plants is more than just a specialty—it’s in our DNA. Since our first…

Read more
Building a Sustainable Process Optimisation Program for Mineral Processing Excellence

Building a Sustainable Process Optimisation Program for Mineral Processing Excellence

We know that process optimisation is a long game. As metallurgists and engineers, we’re in this for the long haul.…

Read more

Subscribe

Enter your details to receive our newsletter

Click here

Contact details

East Tower, Level 4,

410 Ann St,  

Brisbane QLD 4000

  • +61 7 3212 5600
  • sales@mipac.com.au
Linkedin

Solutions

Services

Products

About Us

Copyright Mipac 2025. All Rights Reserved

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Request a
Demonstration

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Simply fill out the below form and we will email you a copy of our TCard brochure.

Simply fill out the below form and we will email you a copy of our MPA product guide.

Simply fill out the below form and we will email you a copy of our SMART Tankhouse brochure.

Download our Capability Statement

Simply fill out the below form and we will email you a copy of our Capability Statement.

[contact-form-7 id="7624"]

Download our OT Vision to Delivery brochure

Simply fill out the below form and we will email you a copy of our Capability Statement.

[contact-form-7 id="7623"]

Simply fill out the below form and we will email you a copy of our E-Learning Brochure.

Request a
Demonstration

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

[contact-form-7 id="8762"]

Download TCard Case Study

Simply fill out the below form and we will email you a copy of the MIM Case Study.

[contact-form-7 id="8768"]

Register for Webinar

Simply fill out the below form and we will send you the details of the webinar directly to your email.

[contact-form-7 id="8833"]

Request a
Demonstration

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Request a
Demonstration

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Simply fill out the below form and we will email you a copy of our TCard™ product guide.

Simply fill out the below form and we will email you a copy of our MPA Logsheets product guide.

Simply fill out the below form and we will email you a copy of our Digital TARP product guide.

Simply fill out the below form and we will email you a copy of our Capability Statement.

Simply fill out the below form and we will email you a copy of our ShortMeter™ product guide.

Simply fill out the below form and we will email you our Copper Monitor™ product guide.

Simply fill out the below form and we will email you a copy of our SMART Tankhouse product guide.

Simply fill out the below form and we will email you a copy of our Alarm Manager product guide.

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Simply fill out the below form and we will be in touch to discuss the best time for a demonstration.

Simply fill out the below form and we will email you a copy of our Copper Monitor brochure.