throughput is more consistent and maintenance is more efficient.” Metrics Manager™ Pro brings together information collected across the MOTION METRICS™ platform into a unified reporting environment, allowing mine and plant personnel to monitor production performance, equipment health and operational trends from a single interface. Within the processing plant, NEXT intelligent solutions continuously monitors equipment health by analysing vibration, temperature, torque and other operating parameters. Rather than relying on fixed maintenance schedules, mines can adopt predictive maintenance strategies that identify developing problems well before failures occur. “This allows maintenance to be planned around production schedules so that mines can reduce unplanned downtime while extending equipment life and lowering maintenance costs,” he points out. Weir’s digital ecosystem also includes digital twin capabilities, which strengthen predictive maintenance by modelling equipment behaviour and forecasting potential failures in advance. “For many mining customers, where a single hour of unexpected downtime can cost hundreds of thousands of dollars, these predictive capabilities offer substantial financial value,” Ayirebi notes. Rather than treating individual machines as isolated assets, Weir focuses on optimising complete processing circuits. Its mine- to-mill philosophy connects blasting, loading, crushing, grinding, classification and tailings management into a single integrated performance strategy. “By helping customers improve fragmentation during blasting, we can enable more efficient crushing,” he explains. “In turn, better particle size consistency enhances grinding performance and mineral recovery downstream.” Within the processing circuit, Weir combines technologies including ENDURON® screens, WARMAN® pumps, CAVEX® hydrocyclones, ENDURON® high pressure grinding rolls (HPGRs), GEHO® PD pumps and vertical stirred mills to maximise throughput while minimising energy consumption. “As with their counterparts globally, mines in West Africa are focused on energy efficiency as part of their ambitious ESG objectives, while also managing rising electricity costs,” he says. “Replacing conventional milling circuits with the ENDURON HPGR and stirred mill technologies, for instance, can reduce energy consumption by as much as 40%.” Ayirebi adds that Weir embeds intelligence directly into its equipment portfolio rather than offering digital products as standalone software packages. Sensors installed on pumps, screens, hydrocyclones, mills and other processing equipment continuously monitor operating conditions and equipment health, while cloud-based analytics consolidate this information into integrated dashboards that provide plant operators with a complete operational overview. “Importantly, these systems are designed to integrate with equipment supplied by other original equipment manufacturers,” he emphasises. “Customers can therefore improve overall circuit performance without replacing existing assets.” According to Ayirebi, the appetite for intelligent mining solutions across West Africa continues to grow. “We define our success not by the number of pumps, cyclones or screens we provide, but by the operational outcomes those technologies help customers achieve,” he concludes. n
AI, sensors and cloud analytics provide real-time visibility across every stage of mining operations.
Digital monitoring helps mines reduce downtime, extend equipment life and lower maintenance costs.
chain with solutions like Micromine® Geobank and Micromine® Origin support drilling programmes, resource evaluation and geological interpretation, while Micromine® Alastri is a mine planning solution and Micromine® Pitram is a real-time fleet management and mine control system. “This upstream intelligence provides a stronger foundation for downstream processing by ensuring that mining activities are aligned with optimal resource extraction strategies,” he says. Once mining is underway, MOTION METRICS™ technologies provide continuous visibility into material movement throughout the operation. AI-enabled fragmentation analysis evaluates blasted rock size to optimise downstream crushing efficiency, while ShovelMetrics™, TruckMetrics™ and BeltMetrics™ measure loading volumes, payloads and material flow throughout the mine- to-mill process. “One particularly valuable capability is continuous AI-enabled G.E.T. Monitoring, compatible with all types of shovels and loaders, which detects broken bucket teeth before they enter crushers or processing equipment,” he says. “By preventing these foreign objects from causing equipment damage, mines can avoid potentially lengthy and expensive shutdowns.” These monitoring technologies combine imaging systems, electromagnetic sensors and sophisticated analytics to provide operators with accurate production dashboards, alarms and performance reports that support better operational decision-making. “The practical benefits of these technologies extend well beyond equipment monitoring,” Ayirebi says. “Customers are already seeing measurable improvements in mine planning accuracy, crusher availability and truck loading efficiency, while
November 2026 | www.modernminingmagazine.co.za MODERN MINING 23
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