How a Digital Mine Management Platform Transformed Operations at Multiple Mining Sites

Reactore

July 23, 2025

Creative Team

Integrated Mining Intelligence System (IMIS)

Real-time Visibility and Control Over Land Acquisition, Lease Tracking, and Geo-referenced Plot Management Across Multi-mine Operations

30%

More Load Per Hour

20%

Less Loss

20%

Less Tare Weight Discrepancy

30%-40%

Faster Dispatch

At a Glance

Commodity

Bauxite

Mine Type

Open Cast

Sites

27

Key Integrations

SAP ERP
Datamine
Weighbridge

Key Business Impact

30-40% faster dispatch transactions

15-25% improved stockpile reconciliation

Solutions

Dashboards
Reports
Mobile Applications

This Solution May be Relevant to You If

  • Your mine has disconnected data sources across land, logistics, production, and safety
  • You rely on spreadsheets, paper logs, or WhatsApp to compile operational reports
  • Material losses or grade dilution are impacting commercial performance
  • Contractor payments are often estimated rather than verified
  • There's limited real-time visibility across stockyards, haulage, or dispatch
  • Compliance reporting for leases or safety incidents is still manual

About the Client

The end user is one of India’s largest bauxite mining and aluminium production companies, operating 27 mining leases across four states with an Environmental Clearance capacity of 15 million metric tonnes. Known for its commitment to sustainability and process innovation, the company required a scalable, real-time digital mining solution to unify its operations across diverse mine clusters.

Note: Client name has been anonymised in accordance with confidentiality agreements.

The Challenge

The end user faced several critical operational challenges:

01

Data Fragmentation across disconnected systems (land, logistics, operations).

02

Manual Logging of production data, leading to delays and inconsistencies.

03

Limited Real-Time Insights into stockpile status, material grades, or fleet movement.

04

Compliance Risks in lease tracking, contractor billing, and HSE monitoring.

05

Difficulty in Scaling Existing Digital Tools to Support Multi-site Integration

The company needed an enterprise-grade digital mining platform to centralise operational data, increase decision-making speed, and ensure compliance across its expanding footprint.

The Solution: MineOne 360° – Integrated Mining Intelligence System

Reactore deployed its flagship solution, MineOne 360°, to unify the end user’s operations across the value chain. Using modular, API-driven architecture, we digitised everything from land acquisition and mineral reserve modelling to logistics, dispatch, contractor oversight, and safety compliance. The solution and modules were customised to curate the solution to address the business requirements acutely.

Integrated Modules Implemented:

Land and Lease Management

GIS-based Lease Tracking, Digital Renewal Workflows, Unified Land Procurement View

Mine Operations dashboards

Mobile Data Capture for Blasting, Excavation, and Crushing; Centralised Dashboards

Mineral Reserve Modelling

Datamine Integration, 3D Orebody Visualisation, Dynamic Grade Estimation

Stockpile and Logistics Control

Real-time Stockyard Visibility, Weighbridge Integration, Rope Conveyor Tracking

Contractor Management

Performance-based Billing, Downtime Tracking, Task Completion Monitoring

Dispatch and Reconciliation

RFID Vehicle Authentication, Automated Material Reconciliation, Multi-Point Validation

Reporting and Decision Support

Live Dashboards, Historical Data Analytics, Auto-Generated Reports

Safety and Sustainability

Mobile-enabled Incident Reporting, Geo-fenced Hazard Zones, Automated Compliance Reporting

The IMIS mobile showing an offline map with site boundary
The IMIS mobile showing an offline map with site boundary.
An individual point plotted to form a geofence that facilitates user to update the geofenced area.
An individual point plotted to form a geofence that facilitates user to update the geofenced area.
A questionnaire-based checklist on the Integrated Mining Intelligence System mobile app.
A questionnaire-based checklist on the Integrated Mining Intelligence System mobile app.
A glimpse of how the IMIS mobile app looks on an industrial tablet.
A glimpse of how the IMIS mobile app looks on an industrial tablet.

Detailed Business Requirements and their Corresponding Solution

Challenges
Solution
Result

Safety and Compliance Visibility Gaps

Safety and Sustainability Application

Automated HSE Alerts, Live Compliance Status Tracking

Contractor Billing Inaccuracies

Performance-based Contractor Management

Verified Payments Linked to Real-Time Equipment Usage

Railway Siding Data Loss

Railway Siding Monitoring Integration

Accurate Siding Records, Better Material Flow to Plant

How We Did It

To execute the implementation of the Integrated Mining Intelligence System (IMIS) effectively, we embraced a comprehensive process consisting of web app development, mobile app development, testing, and deployment.

Site Analysis and Digital Readiness Assessment

Reviewed Workflows, Identified Technical Gaps, Mapped Systems and Infrastructure

Web and Mobile App Development

Custom Dashboards and Mobile Apps Built For Mine Managers, Supervisors, and Operators

Systems Integration

APIs Developed for Seamless Interoperability with Datamine, ERP, LIMS, Drone Surveys, Weighbridges, and Rope Conveyors

Testing and Phased Rollout

Iterative UAT, Training, and Go-Live Across Regions with On-ground Support

Business Impact

Quantitative Improvements

30–40%

Faster Dispatch Transactions

How It Was Achieved

Integrated Weighbridge Data, Automated Truck Authentication, and Real-time Dispatch Dashboards

20%

Increase in Grade Blending Accuracy

How It Was Achieved

Dynamic Grade Estimation from Reserve Modelling System Integrated with Blending Logic

50–75%

Reduction in Contractor Billing Disputes

How It Was Achieved

Automated Performance-based Payments tied to Equipment Logs and Actual Task Completion

5–10%

Uplift in Equipment Utilisation

How It Was Achieved

Mobile Operations Logging and Contractor Performance Monitoring using Real-time Dashboards

15-25%

Improved Stockpile Reconciliation

How It Was Achieved

Geo-tagged Stockyard Mapping, Movement Tracking, and Digital Stockpile Dashboards

Qualitative Benefits

Faster

Decision Making and Exception Handling

HOW WE ACHIEVED

Live Dashboards and Scheduled Alerts Enabled Near Real-Time Visibility for Supervisors and Planners

80-100%

Automation of Manual Reporting

HOW WE ACHIEVED

Field Operations and Compliance Reporting Handled Via Real-Time Mobile Forms and Auto-Generated Dashboards

Full Digitalisation

Lease and HSE Workflows

HOW WE ACHIEVED

LMS For Land Records and Mobile-based Safety Monitoring Applications Replaced Paper-Based Processes

90%+

Operational Data Centralisation

HOW WE ACHIEVED

Unified Platform Integrating Data from Mobile Apps, ERP, Drone Surveys, Weighbridges, and PLC Systems

*Benefits and performance improvements are based on observed operational outcomes and internal benchmarks during and after deployment. Results may vary depending on site conditions and implementation scope.

Why the End User Chose MineOne 360°

Scalable and Modular Architecture

Adaptable to the end user’s multi-state, multi-lease complexity

Integration Flexibility

Seamlessly works with existing tools like Datamine, Oracle, and SCADA systems

Offline Mobile Capability

Empowered field teams even in low-connectivity environments

Proven Track Record

Reactore’s success in implementing digitalisation solutions for mines in India and around the globe

Real-time Operational Insights

Improved control and responsiveness at every level

Ready to digitally transform your Mining Operations?

Explore how MineOne 360 can unify your value chain — from pit to port — with real-time insights, modular flexibility, and enterprise-grade scalability. Learn More

Improve Productivity, Safety and Reduce Risk

Get in touch with one of our mining technology gurus and learn how Reactore can assist with digital transformation possibilities.

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