Data-Driven Services Help Mining Companies Unlock Operational Value

Metso has surpassed 800 connected pieces of equipment under its Data-driven Performance Services, marking a significant expansion of the company’s digital service offering for the mining and minerals processing industry. The number of connected assets has more than doubled since the services were introduced in September 2025.

The service combines equipment connectivity, standard instrumentation, advanced analytics, artificial intelligence and failure modes and effects analysis (FMEA) to identify developing equipment issues before they lead to unplanned shutdowns. According to Metso, the approach enables customers to improve maintenance planning, increase equipment availability and reduce operational risk.

The company says the service currently detects 80–90% of developing equipment issues. Based on customer experience, equipment availability has improved by up to 6%, while CO₂ emissions have been reduced by as much as 20% per tonne through more efficient operations.

“Connected equipment enables fast analysis and actions through Metso Data-driven Performance Services,” said Arttu-Matti Matinlauri, Vice President, Minerals Digital at Metso. He added that the company’s Performance Centers combine equipment expertise with AI-driven analytics to support predictive maintenance and operational decision-making.

Predictive maintenance delivers operational benefits

Metso says its digital services allow customers to monitor individual assets as well as entire process islands, providing a broader view of plant performance. Early detection of equipment degradation enables maintenance work to be scheduled before failures occur, reducing unplanned downtime and improving production reliability.

According to the company, real-world applications have demonstrated reductions in unexpected shutdowns while helping operators avoid costly equipment failures through proactive maintenance.

South American mine reports multi-million-dollar savings

Metso highlighted results from a customer site in South America, where the Data-driven Performance Services have been used to support condition monitoring and field maintenance.

During the first six months of operation, the system identified 94% of detected operational risks, allowing potential failures to be addressed before they affected production. According to Metso, the project prevented more than 215 hours of potential downtime and reduced spare parts consumption, generating an estimated value of USD 7.4 million.

“The results demonstrate how our Data-driven Performance Services are improving our customers’ operations and supporting their ambition to stay at the forefront of the industry,” said Pablo Zuniga, Director, Performance Services at Metso.

The expansion reflects the mining industry’s increasing adoption of digital technologies to improve equipment reliability, optimise maintenance strategies and reduce operating costs as operators seek higher productivity and more sustainable mineral processing.