Context. A large-scale mining operation in strategic minerals, in Brazil, running continuous beneficiation with grade control. Plant documentation was scattered and incomplete, insufficient to support any optimisation project.
The real problem. The operation wanted to optimise internal logistics and batch traceability, and had no basis for it. Without a reliable model of the physical process, any simulation would be guesswork and any automation would be done blind.
What we did. We surveyed and modelled the complete process flow in 3D, in SolidWorks: raw material intake, blending and grade and quality control, dispatch and truck loading, covering 37 pieces of equipment including conveyors, presses, packers, robots and forklifts. On top of that model we enabled Digital Twin execution on an Nvidia platform, and integrated industrial networks and communication protocols directly into the ERP and the Track and Trace systems.