Advanced process control for mineral processing
Powering the future of mineral processing
IntelliMet combines advanced process control, intelligent instrumentation and real-time plant data to take mineral processing operations from manual intervention to full plant automation. Measurable, reliable, step by step.
Our mission
From measurement to full plant automation
Transforming mining and metallurgy through powerful yet affordable control, instrumentation and analytics solutions that deliver measurable operational impact.
Advanced Process Control
Stabilise, then optimise. Model-based control strategies that reduce variability, push constraints and keep your circuits at their optimum, 24 hours a day.
- Circuit stabilisation & constraint pushing
- Mill, flotation & thickener control
- Energy distribution optimisation
Intelligent Instrumentation
The measurements that matter, made reliable. From froth cameras and particle-size analysers to full instrumentation gap audits and upgrades.
- X-trac belt vision & X-flow froth cameras
- Online particle size analysis
- Instrumentation gap analysis & procurement
Data & Metal Accounting
A single source of truth for the plant. Automated metal accounting, mass balancing, downtime management and compliance, powered by the InSite platform.
- Automated metal accounting & reconciliation
- Real-time & historical dashboards
- Downtime and compliance tracking
AI & Machine Learning
Machine learning models that solve complex metallurgical challenges: digital twins, outlier detection and forecasting of recoveries, mass pulls and grades.
- Digital twins & soft sensors
- Forecasting & anomaly detection
- Correlation & performance analytics
Our platform
One connected plant
InSite turns plant data into decisions; X-trac and X-flow turn cameras into instruments. Together they form the digital backbone for advanced control and, ultimately, autonomous operation.
Integrate · Analyze · Optimize
The plant data platform. InSite connects historians, lab systems, weighbridges and manual data into one warehouse with a calculation engine on top, delivering automated metal accounting, live dashboards, downtime management and event-driven reporting.
- Automated metal accounting & mass balancing
- Live dashboards with direct historian connections
- Downtime capture, reporting & reliability analytics
- Compliance tracking from daily checks to annual audits
Machine vision
Cameras that run the plant
Camera-only vision and AI that reads the froth, sizes the feed and acts. Continuously, objectively, never looking away. Built for mining: stainless housings with integrated illumination, on-site edge GPU processing at 15+ fps, and outputs straight to the PLC via OPC UA or Modbus-TCP. Pilots go live in weeks on a single circuit, running alongside existing monitoring.
X-trac
One overhead camera, three jobs
Mounted above the feed conveyor, X-trac runs continuous machine vision on the material stream, replacing periodic sieve samples and walk-by inspections. No sampling, no waiting: sieve samples lag reality by hours, and tramp metal is usually found only after it tears a belt.
Particle Size Distribution
Continuous F80/F95, mm-bin histograms and a live stability index, with no link lost between sizing and live control.
Foreign Object Detection
Tools, idler parts and tramp oversize flagged the moment they appear, with a captured evidence frame for every alarm.
Belt Drift Detection
Live centreline offset in millimetres catches misalignment before it damages the belt or takes out an idler.
F80 / F95 · mm-bin histograms · FOD alarms with evidence frames · belt centreline offset · OPC UA / Modbus-TCP
X-flow
A flow meter on every cell
A metallurgist runs a flotation cell by eye. X-flow is that metallurgist on every cell, 24/7: velocity vectors traced across the froth surface on every frame, combined with froth height to meter the concentrate flowing over the lip. The same judgement at 3am as at shift handover.
Live mass pull
Froth volume recovery (velocity × height × lip length) gives a live m³/h reading per cell. Push the pull or back off with a live number in front of you, not a shift-old sample.
Balance the bank
Every cell reports its own pull. See which cells are loaded and which are starving, and correct maldistribution instead of guessing from one bank-level number.
Peak Air Recovery control
The PAR controller hunts the optimum air rate automatically: stepping air up as froth recovery climbs, reversing past the peak, then holding it with small bracketing steps.
Froth velocity (m/s) · froth volume recovery (m³/h) · per cell, not per bank · straight to the PLC
The idea behind our cameras
Artificial Intuition
An experienced metallurgist can glance at a flotation cell and know, within seconds, what is wrong. That instinct is not magic. It is years of watching froth and belts, and tying what they saw back to the data. Artificial Intuition is that same ability, engineered into a machine.
See
X-trac and X-flow watch the belt and the froth the way a metallurgist does: continuously and objectively, in millimetres and metres per second, on every shift.
Learn
Every camera is deployed with a base layer of control, then grows: machine-learning models seeded with the experiential knowledge of practising metallurgists, correlated live against plant data in InSite.
Conclude
By linking what it sees to what the plant does, each camera reaches conclusions no conventional instrument can. Judgement calls, not just measurements.
Over time, each camera becomes a virtual metallurgist on its piece of equipment: on shift 24/7, never distracted, never looking away. The kind of operator that can tell you:
“This froth is too brittle. Increase collector dosage.”
Why IntelliMet
What sets us apart
Built by metallurgists
Our solutions are designed and supported by mining and metallurgical professionals who have run the plants they now automate.
Affordable by design
Enterprise-grade capability at a fraction of the cost of traditional vendors. Value first, licence fees second.
Simple, not simplistic
We make big data small again. Clean interfaces, clear numbers, decisions your team can act on.
Flexible implementation
Solutions that adapt to your operation and scale with your growth, from a single circuit to the full flowsheet.
Measurable impact
Every deployment is tied to recovery, throughput, uptime or cost, tracked in the same platform that runs your plant.
Credentials
Certified expertise
The team behind IntelliMet holds internationally accredited certifications in artificial intelligence and lean operations, the two disciplines our solutions are built on.
Certified Artificial Intelligence Practitioner
CAIP · CertNexus
A vendor-neutral, ANAB-accredited certification (ISO/IEC 17024) covering the design, training, evaluation and deployment of machine-learning and AI solutions.
Certified Lean Management Professional
CLMP · Six Sigma Management Institute Asia
A lean operations and continuous-improvement certification from the institute of Dr. Mikel J. Harry, co-creator of Six Sigma.
How we work
Quick wins early, value that compounds
We follow an agile implementation methodology: short sprints that bring early results while steadily increasing value over time. Prove the value on a single circuit first, then scale with confidence. No big-bang cutovers, no stalled megaprojects.
Discovery
Digital readiness assessment: control system, instrumentation, network and historian audit with a prioritised gap analysis.
Foundation
Close the critical gaps in instruments, OPC UA and historian access, then stand up the data platform.
Automation
Automated metal accounting, dashboards and downtime tracking go live; first control loops commissioned.
Optimisation
Advanced control, machine vision and ML models push the plant towards autonomous operation.
Where to start
Is your plant ready for automation?
Our Digital Readiness Assessment maps your PLCs, instrumentation, networks and historians against what full plant automation requires, and gives you a phased, costed path to close the gaps.
Contact
Let's automate your plant
Tell us about your operation and we'll come back with a practical first step, usually within one working day.