This article is part of our Golden State content series, based on the webinar “From Chaos to Clarity: Navigating Process Variability with Confidence.”
👉 Watch the full webinar here to explore how leading sites are tackling variability with smarter thinking and real-time decision support.
Or watch this 3 minute snapshot on the hidden cost of variability.
How to reduce process variability in mineral processing in 2026 and why it still matters
As we head into 2026, process variability remains one of the most persistent and costly challenges in mineral processing. Despite advances in automation and instrumentation, many operations still struggle to detect, understand, and control the subtle shifts that erode performance.
This article explores why variability is still the “silent killer” in mining operations, and how Mipac’s Golden State application is helping metallurgists and operations superintendents take back control.
What is process variability and why is it so hard to control?
Process variability refers to fluctuations in key parameters like feed grade, ore hardness, reagent dosing, and operator behaviour. These changes often don’t trigger alarms, but they quietly impact throughput, recovery, energy use, and stability.
In many plants, data is fragmented:
- Lab results arrive hours later.
- Control system trends are siloed.
- Manual logs are stored in spreadsheets or notebooks.
- Experienced operators and their tribal knowledge are retiring.
The result? Teams firefight symptoms without understanding root causes. Production deviations go unsolved until the next day. And opportunities for improvement are missed.
Golden State helps metallurgists and superintendents reduce variability
Golden State, part of the MPA suite by Mipac, is a real-time decision support tool designed specifically for minerals processing operations.
It integrates data from AVEVA PI AF, lab systems, and manual inputs to provide a contextualised, visual view of process outcomes and their drivers. This allows teams to:
- Detect deviations early
- Understand cause-and-effect relationships
- Take corrective action before performance is lost
Golden State doesn’t just show data; it shows what matters, when it matters.
How does Golden State support operators and new team members?
In 2026, many sites will be facing an experience gap. As senior operators retire, newer team members are expected to make high-impact decisions with limited context.
Golden State bridges this gap by:
- Visualising process behaviour in real time
- Highlighting deviations and their contributing drivers
- Supporting consistent, confident decision-making
This helps operators move from reactive to proactive and gives metallurgists a shared language to align teams across shifts and departments.
What is Short Interval Control and how does Golden State enable it?
Short Interval Control (SIC) is a structured approach to reviewing performance in near real time, typically every 2–4 hours, rather than waiting for daily meetings.
Golden State enables and shortens the SIC period by:
- Providing live visibility of key process outcomes
- Highlighting, in real-time, which drivers are trending out of range
- Supporting structured escalation and corrective action
This helps teams stay on track throughout the shift and transforms production meetings from post-mortems into planning sessions.
What does Operational Excellence look like in 2026?
Every site is different. But the principles of operational excellence are the same:
- Clarity of process performance
- Alignment across teams
- Confidence in decision-making
Golden State helps you define your own “Golden State” – your site’s version of optimal performance – and gives your team the tools to achieve it.
Ready to reduce variability and improve performance?
If you’re looking to reduce process variability, empower your operators, and make your production meetings more effective in 20265 and beyond, Golden State can help.
