P80 Sizing

Ensure predictable, consistent, material sizing from crushers to milling operations
Ensure predictable, consistent, material sizing from crushers to milling operations


Ensure predictable, consistent, material sizing from crushers to milling operations

Consistency and predictability are the keys to efficient operations in processing plants. Often the focus in crusher operations is on volume and attention is on feed rate, tons/hour, downtime and delays. What is commonly lost is the attention paid to the consistent sizing of material passing from the crushers to the mills. Ironically, this quality metric has a direct impact on volume since inconsistent and oversized material requires more dwell time in milling which reduces throughput and increases energy costs.

There are several factors that require interdepartmental communications such as fragmentation, feed rates, density, grade, contaminants and dilution (processing waste versus ore). However, P80 sizing is one control point that is largely within control of processing plants.

Key Client Challenges:

  1. How can we reduce the variability in P80 sizing to ensure consistent product quality and maximize recovery?
  2. What are the most reliable and advanced particle size measurement technologies available, and which one is best suited for our specific ore processing operation?
  3. What strategies can help us maintain the desired P80 size even when faced with variations in ore feed characteristics?
  4. How can we optimize the operation of our grinding and milling equipment to achieve more accurate P80 sizing while minimizing energy consumption and wear and tear on equipment?
  5. What steps can we take to improve the representativeness of our ore samples, and how frequently should we collect samples for P80 analysis?
  6. How can we leverage real-time data and process control systems to continuously monitor and adjust our operations for accurate P80 sizing?
  7. What are the key factors within our ore processing circuit that are currently affecting P80 sizing accuracy, and how can we address these issues?

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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