Hindustan Zinc Boosts Mining Efficiency with IIoT Fleet Intelligence

03 Nov 2025 CW Team

Over FY24–FY26, the system has achieved measurable improvements across key equipment categories — with Jumbo drilling machines recording a 28 per cent increase in uptime, Load Haul Dumpers 24 per cent, and Low-Profile Dump Trucks over 27 per cent. Energy efficiency has also improved, with the Power Pack to Percussion ratio for Jumbo machines enhancing from 3.8 to 3.4, indicating optimised energy use and reduced operational waste.

“With stronger data capture, IIoT integration, and analytics, we’re moving from reactive to predictive operations,” said Arun Misra, CEO, Hindustan Zinc. “This project is a clear step towards smarter, real-time decision-making and building an energy-efficient mining ecosystem.”

The company’s Collaboration Centre serves as the digital hub integrating data from sensors, fleet systems, and IIoT devices developed with Machine Max, a Vedanta Spark startup partner. This setup enables real-time analytics, faster interventions, and improved planning across operations.

Aligned with its broader automation and sustainability goals, Hindustan Zinc continues to partner with over 20 technology startups under Vedanta Spark, driving innovations in AI, robotics, and drone-based monitoring. These initiatives reinforce the company’s commitment to transforming mining with safety, efficiency, and sustainability at its core.

Technology

Hindustan Zinc

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Hindustan Zinc, India’s largest integrated zinc producer and among the top five global silver producers, has advanced its smart mining strategy through an Industrial Internet of Things (IIoT)-powered fleet intelligence system. The initiative benchmarks the reliability and energy performance of Heavy Earth Moving Machinery (HEMM) to deliver real-time insights on uptime, reliability trends, and energy consumption. Over FY24–FY26, the system has achieved measurable improvements across key equipment categories — with Jumbo drilling machines recording a 28 per cent increase in uptime, Load Haul Dumpers 24 per cent, and Low-Profile Dump Trucks over 27 per cent. Energy efficiency has also improved, with the Power Pack to Percussion ratio for Jumbo machines enhancing from 3.8 to 3.4, indicating optimised energy use and reduced operational waste. “With stronger data capture, IIoT integration, and analytics, we’re moving from reactive to predictive operations,” said Arun Misra, CEO, Hindustan Zinc. “This project is a clear step towards smarter, real-time decision-making and building an energy-efficient mining ecosystem.” The company’s Collaboration Centre serves as the digital hub integrating data from sensors, fleet systems, and IIoT devices developed with Machine Max, a Vedanta Spark startup partner. This setup enables real-time analytics, faster interventions, and improved planning across operations. Aligned with its broader automation and sustainability goals, Hindustan Zinc continues to partner with over 20 technology startups under Vedanta Spark, driving innovations in AI, robotics, and drone-based monitoring. These initiatives reinforce the company’s commitment to transforming mining with safety, efficiency, and sustainability at its core. Technology Hindustan Zinc

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