Reactore
•
September 25, 2025
Increased Sales (3.85 to 10 mn tonnes/year)
Increased to 4,000-4,500 Trucks Daily
Reduced Processing Time Per Truck
Reduced Turnaround Time
Commodity
Iron Ore
Operation Type
Open-cast Mining, Multi-Block Operation
Operation Sites
1
Key Challenges
Traffic Congestion
Vehicular Conflicts
Limited Safety
Manual Processing
Human Errors
Over-speeding Risks
Compliance Gaps
Key Business Impact
Enhanced Productivity
Improved Safety
Streamlined Traffic
Automated Dispatch
Key Integrations
SAP ERP
Integrated Mines and Mineral Management System (i3MS)
RFID-based Access Control
Weighbridge
Boom Barrier
Traffic Signal
Proximity Alert System (PAS)
IR Sensor
Thermal and Laser Printers
• Your mining operation struggles with traffic congestion and vehicular conflicts.
• You aim to automate stockyard and dispatch management for higher throughput.
• Safety incidents or fatalities have been a concern in your logistics flow.
• Manual transaction processing is slowing down your dispatch cycles.
• You require real-time monitoring of trucks, stockpiles, and sales.
The client is one of India’s largest state-owned mining enterprises, with a diversified portfolio spanning iron ore, bauxite, chromite, and other key minerals. With decades of experience, the organisation plays a pivotal role in powering domestic steel and manufacturing supply chains while also serving international markets. Its large-scale, open-cast operations involve managing some of the country’s most mineral-rich belts, where thousands of trucks pass through mine roads, stockyards, and dispatch points every day. Handling millions of tonnes of ore annually, the enterprise faces inherent challenges of traffic congestion, safety management, and real-time logistics coordination at scale. Renowned for its commitment to operational excellence, safety, and sustainable mining, the organisation continues to invest in advanced technologies to modernise its processes and ensure compliance with evolving regulatory frameworks.
1
Congestion and vehicular conflicts affecting smooth operations.
2
Lack of infrastructure and safety measures across access and transit routes.
3
Multiple manual transaction phases causing inefficiency and human error.
4
Over-speeding and traffic hazards within the mine.
5
Limited visibility across dispatch processes and truck movements.
6
Manual processes increasing driver exposure to accidents.
Reactore deployed the MineOne™ Sales and Dispatch Management System, a fully integrated platform designed to automate and optimise truck movements, dispatch, and logistics in real-time. By combining RFID-enabled access, manless weighbridges, traffic management systems, and a centralised command and control centre, the solution eliminated manual bottlenecks, improved safety, and delivered end-to-end visibility across mining operations.
Integrated Modules Implemented:
Provides real-time visibility of production volumes and automates sales order processing for faster throughput.
Ensures secure, hands-free entry and exit of trucks while eliminating manual permit checks.
Automates truck weighing and access control, reducing delays and human intervention.
Optimises stockpile allocation and truck parking to streamline loading and dispatch flow.
Regulates on-site vehicle movement with automated signals, speed monitoring, and congestion control.
Centralises monitoring and decision-making with map-based dashboards and real-time alerts.
Offers intuitive visual tracking of trucks, stockyards, and workflows for better operational planning.
Automates delivery challan generation and integrates with ERP systems for accurate, compliant order fulfilment.
Traffic congestion and vehicular conflicts
Integrated Traffic Management System (ITMS) with RFID tracking, automated signal operations, and speed violation monitoring
Seamless traffic flow and up to 72% increase in truck transport
Inefficient manual dispatch processing with high turnaround times
Automated weighbridge operations, RFID-enabled truck registration, and mobile-app-based data exchange
98% reduction in processing time per truck, 81% reduction in TAT
Safety hazards due to manual driver interactions at transaction points
Hands-free RFID-enabled checkpoints and emergency communication systems
Zero fatalities after 2020, and 90% increase in driver safety
Manual generation of delivery challans and order tracking created delays, inconsistencies, and compliance risks
Automated challan generation integrated with SAP ERP, linked to RFID and weighbridge data for real-time validation
Reduced errors in documentation, faster order-to-dispatch cycle, and ensured compliance with regulatory systems
Lack of real-time visibility and control over sales and dispatch
Centralised Command and Control Centre with map-based dashboards and KPI-driven reporting
Enhanced monitoring, faster decision-making, and higher operational transparency
The solution was rolled out through close collaboration with the client, ensuring smooth integration of systems and rapid user adoption. A structured transition to operations and maintenance secured long-term reliability and performance.
Conducted gap analysis, traffic management planning, and infrastructure redesign
Integrated SAP ERP, i3MS, RFID Readers, Traffic Signal, Proximity Alert System (PAS), IR Sensor Weighbridges, and Control Room Applications
Rolled out Command and Control Centre and trained operators, drivers, and staff
Started May 2020, transitioned to Operations and Maintenance (O&M) from May 2021 under a 60-month AMC.
Quantitative Improvements
Truck Processing Time Reduced
Automation of weighbridges, RFID-enabled truck registration, and mobile-app-based data exchange.
Material Throughput and Sales Performance Improved from 3.85 mn tonnes/year to 10 mn tonnes/year
Automated sales and dispatch management with real-time monitoring and KPI tracking.
Truck Transport Capacity Increased to 4,000-4,500 Trucks Per Day
Integrated traffic management system and optimised route planning.
Turnaround Time (TAT) Dropped Significantly
Centralised dispatch scheduling and automated workflow management.
Qualitative Benefits
Workforce and Driver Safety
Hands-free RFID-enabled checkpoints, emergency communication systems, and continuous monitoring.
Reduced Manual Documentation and Faster Processing
Hands-free data exchange using RFID and mobile applications.
Faster Decision Making
Map-based dashboards, KPI-driven reporting, and command-and-control centre integration.
Regulatory and Compliance Improvements
Continuous monitoring systems, automated violation detection, and integrated compliance reporting.
*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.
Decades of domain experience in large-scale mining automation and logistics ensured confidence in delivery.
End-to-end coverage across sales, dispatch, traffic, safety, and stockyard operations with seamless ERP integration.
Designed to handle multi-block, high-throughput operations with the flexibility to expand across future sites.
Hands-free RFID checkpoints, automated alerts, and compliance-driven monitoring strengthened workforce and driver safety.
Integrated with SAP ERP and i3MS to ensure transparency, traceability, and adherence to mining regulations.
Backed by a 60-month operations and maintenance contract for continuous reliability and performance.
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
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