Udaipur, October 31, 2025 - Hindustan Zinc Limited, India’s only and the world’s largest integrated zinc producer, and among the world’s top five silver producers, is advancing towards smart mining with a fleet intelligence system driven by the Industrial Internet of Things (IIoT).

To benchmark the reliability and energy performance of heavy earth-moving machinery, the company is continuously monitoring real-time equipment uptime, reliability trends and energy consumption data through comprehensive initiatives. These predictive insights are proactively optimising operations, enabling seamless performance and rapidly optimising energy usage. This efficiency enhances machine life and overall productivity.

Over the past three financial years, from FY24 to FY26, this data-driven approach has delivered significant and measurable improvements across key equipment categories. Jumbo drilling machines achieved a 28% improvement in reliability and uptime, operating longer with more consistency. Load haul dumpers recorded a 24% increase in uptime, while low-profile dump trucks showed an improvement of more than 27%. Efficiency has also improved, as reflected in the lower power pack to percussion ratio, which indicates optimised energy usage for equivalent output. For jumbo machines, this ratio improved from 3.8 to 3.4, highlighting refined control and higher energy efficiency. These results underline the company’s strong maintenance culture, disciplined operations and the alignment of design excellence with equipment performance.

At the heart of this transformation is Hindustan Zinc’s advanced Collaboration Center, which acts as the central nerve system for real-time data integration and decision-making. All data collected from multiple sources — from plant systems and sensors to fleet-level IIoT devices — seamlessly flows into the digital hub, deployed in collaboration with Vedanta Spark startup partner MachineMax.

Through Vedanta Spark, Vedanta’s global corporate accelerator and enterprise programme, which collaborates with innovative startups to drive large-scale transformative impact by addressing critical business challenges through emerging technologies, Hindustan Zinc has leveraged high-impact opportunities using Artificial Intelligence, Machine Learning, Computer Vision, Drone Solutions, Internet of Things and Augmented/Virtual Reality. By bringing operations, maintenance and analytics under one roof, the Collaboration Center enables faster interventions, improved planning and a unified view of performance across the value chain.

This digital initiative is an integral part of the company’s broader strategy for automation, smart mining, and sustainability. By implementing advanced technologies, Hindustan Zinc builds strong decision-support systems and provides real-time visibility into critical processes, delivering substantial improvements in operational efficiency, equipment uptime, and predictive maintenance across its entire operations.

Hindustan Zinc continues to drive innovation in the metals and mining sector by implementing advanced technologies that enhance safety, efficiency, and sustainability. Currently, Hindustan Zinc is working on more than 50 projects with over 20 technology startups through Vedanta Spark. The company collaborates with startups across key areas including production growth, cost optimisation, value creation, ESG (environmental, social and governance) leadership, and improved safety practices.

Hindustan Zinc has integrated technological excellence and innovation across its operations, including robotics, artificial intelligence, blockchain, and the Industrial Internet of Things. Recently, the company announced the implementation of an advanced AI-powered camera surveillance system across its operations. This innovative solution ensures workplace safety, operational efficiency, and compliance monitoring, resulting in approximately 50% reduction in manual intervention. Additionally, the company has deployed robotic automation in high-temperature smelting operations, enhancing precision, streamlining metallurgical workflows, and ensuring consistent product quality.

In the future, Hindustan Zinc is set to introduce LiDAR-enabled drone-based stope scanning to improve the accuracy of underground mine mapping and optimise extraction planning. Through these innovations, Hindustan Zinc is redefining the future of mining in India and setting new global standards for the industry.

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