Grading & Gauging

Improve accuracy of sensor calibration and ore grading in processing plants
Improve accuracy of sensor calibration and ore grading in processing plants


Improve accuracy of sensor calibration and ore grading in processing plants

In mine process plants, gauges, or instruments and sensors, are often found to be offline, faulty or incorrectly calibrated. In cases such as these, visual inspections can do little good since what cannot be measured accurately cannot be managed effectively.

With various sensor technologies such as X-ray fluorescence (XRF), near-infrared (NIR) spectroscopy, and gamma-ray sensors used for ore grade analysis, calibration requires technical expertise by skilled workers and can remain difficult in harsh mining environments. Managing ore variability and ensuring consistent grading and gauging is also a common challenge, with inaccurate grading leading to inefficient processing and reduced ore recovery rates.

However, by leveraging real-time monitoring of ore grades as they move through the processing plant, processes can be controlled and optimized to reduce delays and inaccuracies.

Key Client Challenges:

  1. What are the most advanced sensor technologies available for accurate ore grading, and how can we implement them effectively in our processing plant?
  2. How can we ensure that the samples collected are truly representative of the entire ore stream, and what innovations in sample collection and preparation can we adopt?
  3. What role can automation and data analytics play in improving the accuracy and efficiency of our grading and gauging processes, and how can we integrate them into our operations?
  4. What opportunities exist for remote monitoring and control of our processing plant, and how can we reduce our reliance on on-site personnel in remote mining locations?
  5. What sustainability and environmental considerations should we take into account when improving our grading and gauging processes, and how can we align with regulatory requirements?
  6. What training programs and skills development initiatives can we implement to enhance the capabilities of our employees involved in grading and gauging processes?

Leveraging data analytics and machine learning algorithms can help mining companies make sense of the vast amounts of data generated during ore processing. Predictive modeling and data-driven insights can further optimize the grading and gauging process.

Nonetheless, skilled personnel are critical to operating and maintaining grading and gauging equipment, as well as interpreting the data provided. At Unison Mining, our subject matter experts can work with your teams to facilitate the training, coaching and resources needed for personnel to accurately and reliably calibrate sensors.

Lacking data to validate or support key business decisions

Lack of knowledge to define a cohesive business or data strategy

Low speed to market and trouble adapting quickly to customer and market needs

High operational costs due to lengthy data processing times


Stockpile Management

Install controls to reduce risks associated with stockpiles including waste buildup.
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P80 Sizing

Ensure material being sent from mines to the processing plant can pass from grinding to milling efficiently and economically
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Advanced Control Rooms

Gain a bird’s eye view of process plant operations with effective utilization of visualization technology.
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Overall Equipment Effectiveness Improvement

Maximize the potential of your equipment to boost ROI and reduce inefficiencies.
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Recovery Improvement

Maximize mineral recovery by improving material handling and separation efficiency.
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Energy Optimization

Reduce energy costs and meet sustainability regulations with reduced energy consumption.
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Shutdown Management

Plan shutdown and turnaround frequencies, durations and intervals with realistic risk planning.
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Line Management

Improve line management through behavior training and coaching for enhanced worker productivity.
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Grading & Gauging

Oversee grade control to ensure that ore sent to the processing plant is of the right quality. Calibrate sensors and instruments effectively for plant operation monitoring.
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Data & Analytics Strategy

Develop a strategy to fully utilize data and analytics for processing efficiency and higher recovery rates.

Throughput Improvement

Minimize resource wastage for improved throughput and financial performance



Our mining experts have experienced first-hand the day-to-day complexities and issues that arise at the mining face, giving them a higher level of understanding and insight to meet your challenges.

Practical Solutions

By implementing level-appropriate transformation tools, our behavioral and cultural change methodologies, data management, and analytics, our goal is to create a sustainable and positive impact on your mining operations.


We go beyond strategy to offer a direct and measurable approach to success. Our commitment extends to delivering real business outcomes and helping your team sustain those changes for the long haul.

Accurately calibrate sensor technology in processing plants to improve ore recovery rates.

Seize this opportunity before you leave!

Ready to take your operations to the next level?

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