Control systems + automation
WRITE @ THE BACK
Strategic upgrades beat obsolescence in mining operations Mining operations are under constant pressure to maintain output while controlling costs. In this environment, operators face one persistent challenge: knowing when and how to upgrade aging systems before they become a liability. Adrian van Wyk, Managing Director, Referro Systems, says: “Striking the right balance through strategic system upgrades is the key to overcoming obsolescence and unlocking sustainable productivity gains.”
For this mine, new solutions were engineered to replace legacy systems within the existing control centres, which meant redesign and downtime could be avoided.
Timely upgrades matter Delay the decision too long, and outdated equipment drags down eiciency, safety, and profitability. Act too hastily, and production risks unnecessary disruption. As downtime can translate into millions of rand lost and customer commitments hinge on consistent productivity, technology upgrades have become essential to sustaining operational excellence and supporting future-ready infrastructure for mining companies around the globe. The value of partnerships Van Wyk highlights the case of one of Referro’s largest mining clients. “Our journey with this client began well before the client’s 2006 automation initiative. Although not formally engaged in their initial programme, our early involvement and deep expertise played a pivotal role in shaping their decision to implement Rockwell Automation’s Allen-Bradley control and motor-control platforms from the outset. Over time, our relationship has transformed – from providing front-line technical support to serving as a trusted advisor and strategic partner, guiding the customer’s long-term automation strategy. This evolution highlights the value of enduring, collaborative partnerships: Referro plays a role in guiding their technology roadmap, ensuring innovation, resilience and forward-thinking is built into every stage of their continuing automation journey.
“Going forward we continue to provide hands-on support, in- depth technical input, and forward-looking advice to ensure the company remains at the forefront of process and automation innovation.” What drives the upgrade wave? The most recent upgrade of the mine’s control systems and motor control centres was motivated by several factors, primarily product obsolescence. For many mines, equipment installed over a decade ago has reached end-of-life, impacting the initially installed product lines and technologies, with manufacturers discontinuing spares and support, forcing mines to consider costly ‘quick fixes’ or risk unplanned downtime. Beyond obsolescence, newer technologies oering faster processing, richer data capabilities, and more robust network protocols created an opportunity. Leveraging these advances through carefully planned upgrades is crucial to maintaining operational eiciency. Seamless engineering Van Wyk emphasises that one of the most complex aspects of any technology refresh is integrating new hardware and so¦ware with existing systems without disrupting ongoing production. “In this case, our engineering teams devised innovative solutions that allowed the replacement of legacy control networks, control
4 Electricity + Control FEBRUARY 2026
Made with FlippingBook flipbook maker