Process Optimisation

Unlock the value in your operation

We can help you optimise your operation

Mipac is your partner in driving operational performance.  

Our experienced and dedicated team can design, configure and advise you on how to optimise your assets so that you can achieve sustainable production improvements and generate more value. 

Taking into consideration your specific challenges, we can effectively optimise your assets for sustained increased productivity, efficiency and reliability. 

See how our approach delivered significant ROI improvements for these 4 customer sites.

Why work with us?

Technical expertise and operational experience across multiple sectors

Our team draws on deep technical expertise and extensive operational experience to solve the most complex of challenges and help you achieve operational excellence.  

As a company, we have over 600 greenfield and brownfield projects under our belt. We have a track record of success and a reputation for delivering value to our clients.  

We work across a range of sectors spanning both small and large cap operators and across various flowsheets and commodities.  

This has given us exposure to leading practices and an extensive network, establishing us as a trusted advisor for our clients.  

Fit-for-purpose, holistic solutions that deliver maximum ROI

Our team looks at the big picture. 

Combining process and automation expertise, we examine the root cause of your challenge and identify production bottlenecks to devise actionable solutions.  

We have global experience in various aspects of mining and metallurgy and can leverage the collective knowledge of Mipac’s instrumentation, control system and production system engineers to solve your operational challenges.  

No matter the commodity, and regardless of which control system you use, we can help you unlock the latent value in your assets and processes to drive increased productivity, efficiency and reliability.  

Check out our ROI case studies.

Services we offer

MAC - Control room with the Main Automation Contracting team

If you work in heavy industry and have complex processes, you could benefit from automation and control. Our team can design and deliver high-quality, proven solutions to help you remain productive, efficient and competitive.  

Whether your aim is to improve performance, implement and tune advanced control strategies or achieve leading practice; Mipac goes beyond the solution.  

We work both onsite and remotely. We also prioritise developing the capabilities of your personnel to enable sustainable long-term improvements based on our recommendations.  

Our solutions:

Focus on providing maximum return on investment

Ensure maximum utilisation of your existing infrastructure

Employ proven technology

Apply relevant layers of the automation pyramid to create value

Are driven by real-world experience

What we can help with

Are you facing any of these common challenges? If so, we can help! 

We can help by:

Our approach

We listen first, working with you to identify constraints across your entire value chain and co-create sustainable, fit-for-purpose solutions that align to your ambitions, budget and timeline.  

Thanks to the breadth and depth of our real-world experience, we have likely stood in your shoes before, so we understand your challenges.  

We’re also experienced in both processing and automation, so we can help you see – and address – the bigger picture. 

In everything we do, we seek to partner with you, knowing that you know your asset best and any solutions we design need to be right for you and your team.   

 Our approach is to: 

discovery, consult, design, implement, review cycle

Our custom process control improvements can help heavy industry operations, like mining, unlock their full potential! In this article you’ll see how we combined an innovative approach with proven results, we make sure our clients get the most out of their business.

See the results at these four mining operations.

Book a discovery call with one of our Optimisation experts today to discuss your specific needs. 

Read more about Process Optimisation

Modernising control systems does not have to mean getting rid of Excel altogether.

Excel: a lifeline or a liability? If you’ve spent any time in mineral processing, you’ve probably worked with Excel for process calculations. …

Process Optimisation program

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

Dark-haired man's headshot on white background.

4 minute read It’s been six months since Process Engineer Andrew Yang made the move from Townsville to Brisbane to join Mipac’s …

Subscribe

Enter your details to receive our newsletter

Did you know?

What is process optimisation in mineral processing?

Process optimisation in mineral processing is improving plant operations across crushing, grinding, flotation and other stages to maximise recovery, increase throughput and reduce energy, water and reagent use. It combines data analysis, process control and continuous improvement to stabilise performance and cut costs.

Why is process optimisation important for mineral processing plants?

Process optimisation in mineral processing helps plants achieve higher recovery, lower operating costs and greater energy efficiency. It reduces variability caused by changing ore feeds and extends equipment life, while improving environmental performance and compliance.

What are the main challenges in process optimisation?

The biggest challenges in process optimisation for mineral processing are ore variability, complex interactions between unit operations, poor data quality and ageing equipment. Plants must also balance trade-offs between recovery, grade, throughput and energy use.

What KPIs measure process optimisation success?

Key KPIs for process optimisation in mineral processing include metal recovery, product grade, energy use per tonne, water consumption, throughput, operating cost, and equipment uptime. Tracking these shows how well a plant is improving efficiency and sustainability.

What are quick wins for process optimisation in mineral processing?

Quick wins include optimising grinding mill settings, adjusting flotation reagents, improving classifier efficiency and scheduling preventative maintenance. Better data collection and sensor calibration also provide low-cost improvements that enhance plant stability and recovery.

How long does it take to see results from process optimisation?

Results vary. Some process optimisation changes in mineral processing, such as reagent adjustments or equipment tuning, deliver improvements in days or weeks. Larger initiatives, like advanced control upgrades or AI tools, can take months to show sustained benefits.

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 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.

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.

Request a
Demonstration

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

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"]

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"]

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