Mining IoT · MineSense IoT

From Pit to Plant,
In Real Time

MineSense IoT turns every sensor, gateway and asset across your open pit, underground workings, processing plant and tailings facility into one live operational picture, with audit-ready compliance reporting and predictive maintenance built in.

  • Gas & air-quality monitoring
  • Predictive maintenance
  • Tailings & slope stability
  • DGMS · CPCB · ICMM ready
Book a 30-minute demoSee the KP Iron case study

Representative panel. Sensor count, uptime and sites are from the KP Iron deployment; alerts and readings are illustrative.

Why mining leaders choose MineSense

Four outcomes the modern mine cannot afford to miss

Mining is judged on four scoreboards at once: safety, compliance, productivity and ESG. MineSense IoT moves all four from one platform.

Safer workforces

Continuous gas, dust, vibration and proximity monitoring, with alerts to the control room and site supervisors in seconds.

Up to 50% faster incident response*

Audit-ready compliance

Every reading, alarm and acknowledgement captured and mapped to DGMS, CPCB, ICMM and ISO frameworks.

100% digital evidence trail

Higher asset uptime

Predictive models on crushers, conveyors, mills, pumps and fans surface failures days ahead, not minutes.

25–40% less unplanned downtime*

Stronger ESG posture

Tailings stability, water quality, air emissions and energy intensity, measured and ready for board and investor reviews.

Live tailings & emissions visibility

* Ranges reflect industry benchmarks for connected-mine deployments. Results vary by site, scope and baseline maturity.

The operating reality

A mine generates millions of data points an hour. Most never reach a decision-maker in time.

Without a connected platform

  • Manual gas and dust rounds leave hours of blind time between readings
  • Conveyor and crusher failures cascade because vibration and bearing trends are reviewed weekly
  • Tailings, slope and seismic data sit in separate vendor portals, so board reporting is reactive
  • DGMS and CPCB inspections take days of paperwork reconstruction
  • New sensors stall because each speaks a different protocol with no shared view

With MineSense IoT

  • One live operational picture across open pit, underground, plant and TSF
  • Threshold and anomaly alerts routed to the right person, with acknowledgement and escalation tracked
  • Models flag bearing wear, belt slip, fan imbalance and pump cavitation days ahead of failure
  • DGMS Form-IV registers, CPCB monthly returns and GISTM disclosures generated in a click
  • A vendor-agnostic edge gateway that speaks Modbus, OPC-UA, MQTT, LoRaWAN, BLE and 4G/5G
Use cases

Nine high-value mining workflows, one platform

Every module is composable. Start with one critical risk area and expand across the operation as the value compounds.

Underground gas & ventilation

Continuous CH₄, CO, H₂S, O₂ and airflow monitoring with zone dashboards, evacuation triggers and ventilation on demand.

Conveyor & crusher health

Vibration, bearing temperature, current draw and belt load feed models that schedule intervention before a stoppage.

Tailings (TSF) integrity

Piezometers, inclinometers, settlement pins, freeboard sensors and pond cameras in one GISTM-ready dashboard.

Slope & pit-wall stability

Radar, prism and InSAR feeds correlated with rainfall and pore pressure for early warning of bench instability.

Air, dust, noise & blast vibration

PM2.5/PM10, NO₂/SO₂, noise and ground vibration streamed to CPCB-compatible reports, with exceedance alerts.

Water quality & discharge

pH, turbidity, conductivity, dissolved oxygen and flow across mine-water circuits, checked against consent limits.

Haul-truck & mobile telemetry

GPS, fuel, engine, tyre pressure and payload data live, with fleet productivity, idle time and dispatch overlays.

Worker proximity & collision avoidance

RFID/UWB tags, BLE beacons and AI cameras enforce no-go zones, pedestrian-vehicle separation and tag-in/tag-out.

Energy & diesel analytics

kWh, diesel and process-electrical loads by asset, shift and ore type, feeding Scope 1 and 2 emissions reporting.

Compliance & reporting

Built around the frameworks your auditors already use

Each sensor reading, alarm and intervention is mapped to the regulation it serves, so audit prep goes from days of spreadsheet stitching to an export.

  • DGMS
    Mines Act 1952 · circulars
  • CPCB / MoEFCC
    Air, water & emissions
  • ICMM GISTM
    Tailings management
  • ISO 45001
    Occupational H&S
  • ISO 14001
    Environmental mgmt.
  • ISO 50001
    Energy management

Out-of-the-box reports

  • DGMS Form-IV style gas registers, with shift-level acknowledgement
  • CPCB monthly returns for ambient air, stack emissions, water discharge and noise
  • Mine manager daily and weekly reports across safety, production and environment
  • TSF and GISTM dashboard packs for board, lender and insurer briefings
  • Reliability MIS: equipment health, MTBF, MTTR and pending predictive interventions
  • ESG quarterly pack: Scope 1 & 2 emissions, energy intensity, water balance and tailings

Immutable audit trail

Every reading, threshold breach, acknowledgement and configuration change is timestamped and signed, defensible in any inspection or incident review.

Role-aware access

Sites → locations → devices → sensors, with access tied to that hierarchy: a safety officer sees all gas sensors, a plant manager the beneficiation circuit, the GM everything.

Predictive analytics

From dashboards that show, to models that predict

  1. 01

    Anomaly detection. LSTM autoencoders and Isolation Forest on multivariate sensor streams catch drift no fixed threshold will.

  2. 02

    Remaining useful life. Time-to-action for rotating equipment from vibration, current, temperature and load signatures.

  3. 03

    Event correlation. Turns an alarm storm into a single root-cause incident with a recommended action.

  4. 04

    Failure-mode classification. Trained on your own work-order history: “bearing race spall”, not “vibration high”.

  5. 05

    Scenario forecasting. Ventilation, water balance, dust dispersion and energy load what-ifs before the shift.

  6. 06

    Model governance. Versioning, drift monitoring and human-in-the-loop overrides your reliability engineers can defend.

RUL · Crusher 2 bearing14 days to action
14d
predicted to threshold breach
at the current operating profile
HealthyDegradingAction zone
Top contributor
Bearing temp ↗ 7 °C in 7 days
Confidence
94%
Recommended
Schedule reseal and lube
Est. saving
~₹38 lakh avoided downtime
SAP PM · Work order opened for the next planned outage window

Worked example from the KP Iron deployment.

Reference architecture

Open at the edge. Hardened in the cloud. Yours either way.

Deploy on Andolasoft-managed cloud, your private cloud, or fully on-premise inside the mine LAN. The platform is the same; data residency, security and integrations stay your choice.

  1. 1

    Sensors

    CH₄ · CO · H₂S · O₂ · vibration · bearing temp · piezometer · level · flow · PM2.5/10 · GPS · vision-AI cameras

  2. 2

    Edge gateway

    Ruggedised IP-67 · Modbus · OPC-UA · MQTT · LoRaWAN · BLE · 4G/5G · satellite fallback · store-and-forward

  3. 3

    Stream & store

    MQTT broker · Kafka · time-series database · object storage · end-to-end encryption

  4. 4

    Intelligence

    Rules engine · anomaly & RUL models · model registry · alarm routing & escalation · workflow API

  5. 5

    Experience

    Web control room · mobile app · HMI tiles · scheduled reports · SAP PM, Maximo, ServiceNow & ERP

Vendor-agnostic by design

Already running Honeywell, Yokogawa, Siemens, ABB or Trolex devices? They plug in. Protocol parity is a checkbox, not a six-month project.

Security first

Zero-trust device onboarding, mutual TLS, signed firmware updates, role-based access and full data-residency options.

Scales with the mine

Built for thousands of sensors per site, multiple geographies, intermittent connectivity and harsh duty cycles.

Client Story · Iron-ore mining

KP Iron Pvt. Ltd.

Iron-ore mining and beneficiation · India

KP Iron runs a multi-pit mine, an on-site beneficiation circuit and a tailings storage facility. It moved four sites and 1,284 sensors off three vendor portals and weekly spreadsheets onto MineSense IoT, reaching 98.2% device uptime and live dashboards in under eight weeks, with no DGMS-reportable gas excursion undetected since go-live.

Read the KP Iron case study

Scope delivered

  • Underground and opencast gas monitoring
  • Vibration and bearing health on conveyors and crushers
  • TSF integrity dashboard, GISTM aligned
  • Air quality and perimeter monitoring
  • Fleet telemetry and Scope 1 emissions feed
  • SAP PM work orders from predictive alerts
  • DGMS Form-IV and CPCB returns from live data
How a deployment runs

Four phases. First value inside the quarter.

Phased and ROI-gated, so leadership sees measurable value before the platform is scaled.

  1. 01~2 weeks

    Discover

    Site walks, sensor inventory, regulatory pain points and a quantified ROI baseline before any hardware is touched.

  2. 02~6–8 weeks

    Pilot

    One site and one critical risk, typically gas, conveyors or TSF, with success criteria signed by HSE and operations.

  3. 03~8–16 weeks

    Scale

    Templated edge rollout, SAP PM or Maximo integration, crew training and progressive activation of analytics.

  4. 04Continuous

    Optimise

    Monthly value reviews, model retraining, new use cases and quarterly compliance posture reports.

Where operations typically begin

Safety-first

Underground gas and ventilation plus worker proximity: the biggest immediate cut in statutory and human-cost risk.

Reliability-first

Conveyor and crusher predictive maintenance plus energy analytics: the fastest path to a hard-rupee ROI on existing assets.

ESG-first

Tailings plus air, water and noise: the strongest improvement to board, regulator and lender posture.

Common questions

MineSense IoT is Andolasoft’s connected-mine platform. It brings sensor monitoring, IoT device management, compliance reporting and predictive analytics for open-pit, underground, processing plant and tailings operations into one live operational picture.

Related

KP Iron case study1,284 sensors across pit, plant and tailings in one control room.Predictive analyticsTime-series models that predict equipment failure before it happens.AI for manufacturingPredictive maintenance and plant analytics on industrial sensor data.

See your mine, in real time, in 30 minutes

Book a private working session with our mining IoT specialists. We will walk a live operational dashboard against your top three risks, whether gas, fixed plant or tailings, and share an ROI model built around your operation.

Request a private demoRead the KP Iron case study

Typical first step: a two-week discovery with a quantified ROI baseline.