####Hindustan Zinc deploys IIoT-Powered Fleet Intelligence to increase mining efficiency

Udaipur, Hindustan Zinc Limited (BSE: 500188 & NSE: HINDZINC) India’s only and the world’s largest integrated zinc producer, and among the top five global silver producers is advancing its journey towards smart mining with a fleet intelligence system powered by Industrial Internet of Things (IIoT). Through a company-wide initiative to benchmark the reliability and energy performance of Heavy Earth Moving Machinery (HEMM), the company is continuously monitoring equipment uptime, reliability trends, and energy consumption data in real time. These predictive insights are actively optimizing operations, enabling seamless performance and sharply optimizing energy use. This efficiency enhances machine lifespan and elevates overall productivity.

Over the last three fiscal years (FY24 to FY26), this data-driven approach has led to significant and measurable enhancements across key equipment categories. Jumbo drilling machines have achieved a 28% improvement in reliability and uptime, operating for longer cycles with greater consistency. Load Haul Dumpers have recorded a 24% rise in uptime, while Low-Profile Dump Trucks have shown an improvement of over 27%. Efficiency has also advanced, as reflected in the Power Pack to Percussion ratio, where a lower value indicates optimized energy use for equivalent output. For Jumbo machines, this ratio improved from 3.8 to 3.4, demonstrating refined control and higher energy efficiency. These outcomes underscore the company’s strong maintenance culture, disciplined operations, and alignment of equipment performance with design excellence.

Reflecting on this achievement, Hindustan Zinc’s CEO – Arun Misra said, “With stronger data capture, cutting-edge IIoT integration, and advanced analytics, we’re moving from reactive to predictive operations. The optimization of our heavy earth-moving fleet has been a game-changer for our uptime and efficiency. This project is a clear step towards smarter, real-time decision-making and building a high-performance, energy-efficient mining ecosystem.”

At the heart of this transformation is Hindustan Zinc’s state-of-the-art Collaboration Centre, which serves as the central nerve for real-time data integration and decision-making. All data collected from multiple sources, ranging from plant systems and sensors to fleet-level IIoT devices deployed in collaboration with Machine Max, a Vedanta Spark startup partner, seamlessly routes to the digital hub. Through Vedanta Spark, Vedanta’s global corporate accelerator and ventures program that collaborates with innovative startups to drive large-scale transformative impact by addressing critical business challenges through emerging technology, Hindustan Zinc has tapped into high-impact opportunities by harnessing technologies like Artificial Intelligence/Machine Learning, computer vision, drone solutions, the Internet of Things (IoT), and Augmented/Virtual Reality (AR/VR). Here, it is processed, analysed, and translated into meaningful insights that empower both frontline teams and strategic leaders. By bringing operations, maintenance, and analytics together under one roof, the Collaboration Centre is enabling faster interventions, smarter planning, and a unified view of performance across the value chain.

This digital initiative is integral to company’s overarching strategy for automation, smart mining, and sustainability. By deploying advanced technologies, Hindustan Zinc builds robust decision support systems and delivers real-time visibility into critical processes, thereby driving substantial improvements in operational efficiency, equipment uptime, and predictive maintenance across its entire operations.

Hindustan Zinc continues to drive innovation in the metals & mining sector by deploying advanced technologies that enhance safety, efficiency, and sustainability. At present, Hindustan Zinc is working with over 20 technology startups on more than 50 projects through Vedanta Spark. The company collaborates with startups in key areas including production enhancement, cost optimization, value creation, ESG (environmental, social & governance) leadership, and improved safety practices.

Hindustan Zinc has embedded technological excellence and innovation such as robotics, artificial intelligence, blockchain, and the Industrial Internet of Things (IIoT), across its operations. Recently the company announced the implementation of an advanced AI – powered camera surveillance system, across its operations. This innovative solution ensures workplace safety, operational efficiency and compliance monitoring resulting in almost 50% reduction in manual intervention. Additionally, the company has deployed robotic automation in high temperature smelting operations, boosting precision, streamlining metallurgical workflows, and ensuring consistent product quality. Looking forward, Hindustan Zinc is set to introduce LiDAR-enabled drone-based stope scanning to elevate the accuracy of underground mine mapping and optimize extraction planning. Through these innovations, Hindustan Zinc is redefining the future of mining in India and setting new global benchmarks for the industry.