Hindustan Zinc Advances Smart Mining with IIoT-Driven Fleet Intelligence

Udaipur. Hindustan Zinc Limited, India’s only and the world’s largest integrated zinc producer and among the top five global silver producers, is driving a new era of Smart Mining with the deployment of Industrial Internet of Things (IIoT)-powered Fleet Intelligence Systems. Through this initiative, the company has achieved record fleet uptime, enhanced energy optimization, and superior operational efficiency across all its mining sites.

By integrating real-time monitoring of equipment uptime, reliability trends, and energy utilization, Hindustan Zinc has established a benchmark in predictive maintenance and data-driven decision-making. These predictive insights are enabling proactive optimization of operations, seamless performance, and accelerated energy efficiency — ultimately extending machine life and boosting overall productivity.

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Data-Driven Performance Gains Across Operations

Over the past three fiscal years (FY24–FY26), this data-centric approach has delivered measurable and sustained improvements across major equipment categories:

• Jumbo drilling machines recorded a 28% increase in reliability and uptime.

• Load Haul Dumpers (LHDs) achieved a 24% improvement in uptime.

• Low-Profile Dump Trucks (LPDTs) improved performance by over 27%.

Efficiency gains are also evident in the Power Pack to Percussion ratio, a key metric reflecting optimized energy use. For Jumbo machines, this ratio improved from 3.8 to 3.4, demonstrating refined control mechanisms and enhanced energy efficiency. These results underscore the company’s strong maintenance culture, disciplined operations, and alignment of design excellence with performance optimization.

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“Moving from Reactive to Predictive Operations” — Arun Misra, CEO, Hindustan Zinc

Commenting on this achievement, Mr. Arun Misra, CEO of Hindustan Zinc, said:

“With robust data capture, advanced IIoT integration, and enhanced analytics, we are moving from reactive to predictive operations. The optimization of our heavy earth-moving machinery has been a game changer for uptime and energy performance. This project marks a significant step toward real-time decision-making and building a high-performance, energy-efficient mining ecosystem for the future.”

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Collaboration Centre: The Digital Nerve Centre of Transformation

At the heart of this transformation is Hindustan Zinc’s state-of-the-art Collaboration Centre, which functions as the central nervous system for real-time data integration and decision-making. The data — collected from plant systems, sensors, and fleet-level IIoT devices — flows seamlessly into a digital hub developed in partnership with MachineMax, a Vedanta Spark startup partner.

Through Vedanta Spark, Vedanta’s global corporate accelerator and enterprise innovation program, Hindustan Zinc collaborates with cutting-edge startups that leverage Artificial Intelligence, Machine Learning, Computer Vision, Drone Solutions, Internet of Things, and Augmented/Virtual Reality technologies. This ecosystem enables rapid intervention, better planning, and an integrated view of performance across the value chain — creating a model for digital excellence in the mining sector.

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Smart, Safe, and Sustainable Mining

This digital initiative forms a key pillar of Hindustan Zinc’s Smart Mining and Sustainability Strategy, aimed at integrating automation, efficiency, and environmental responsibility.

Key technological advancements include:

• AI-powered camera monitoring systems, which have improved workplace safety, operational compliance, and reduced manual interventions by nearly 50%.

• Robotic automation in high-temperature smelting operations, leading to greater precision, streamlined metallurgical workflows, and consistent product quality.

• Upcoming deployment of LiDAR-enabled drone scanning for improved underground mine mapping accuracy and optimized extraction planning.

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Driving Innovation Through Collaboration

Currently, Hindustan Zinc is working on over 50 technology-driven projects in collaboration with 20+ startups under the Vedanta Spark program. These partnerships are delivering transformational results across key focus areas such as production enhancement, cost optimization, ESG leadership, and safety innovation.

By integrating Robotics, AI, Blockchain, and IIoT, Hindustan Zinc continues to redefine operational excellence and set new global benchmarks for the mining industry.

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The Road Ahead

Hindustan Zinc’s journey is a testament to its commitment to technological excellence, sustainability, and safety. With IIoT-enabled fleet intelligence, digital collaboration, and predictive analytics, the company is building a future-ready mining ecosystem that is profitable, sustainable, and globally competitive.

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“Hindustan Zinc — Redefining the Future of Mining through Innovation, Efficiency, and Sustainability.”

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