Case Study: a mining company predicts mill failures and avoids downtime with Falkonry Operational AI

How Falkonry Helped Predict Failures & Avoid Downtime

A mining company faced frequent and costly unexpected downtime at its vertical mill due to blockages caused by variations in ore grade. Long lab assay turnaround times provided insufficient warning of low-grade ore, leading to high repair costs and revenue loss. The company engaged Falkonry to address this challenge using its operational AI software.

Falkonry implemented its AI software to recognize patterns indicating low-grade ore in the mill and provide early alerts. This gave operators visibility to track suspect material and adjust grinding speed to prevent blockages. As a result, the mining company avoided downtime that cost $30,000 per hour and realized an estimated $900,000 in annual cost savings for a single facility.