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Data Driven Improvements to Haul Truck Operations

Reduce crusher downtime with LoadWise

The presence of oversize rocks in the primary crusher can lead to costly downtime and lost production. LoadWise is an automated oversize detection system which can detect oversize ore in the pit as the truck is loaded. This allows trucks to be diverted, preventing crusher downtime. The system provides a simple, hardware and software solution that can quickly be retrofitted to any vehicle straight out of the box. It can provide alarming and indication of a potential crusher blockage event in real- time. In contrast to camera-based systems and other immature prototype solutions, LoadWise is a highly reliable system which can be configured to achieve specific truck diversion rates and material throughput targets.



The system is optimised for easy maintenance, harsh environments and typical mining conditions. It is durable to operate extended periods which reduces the need for replacement which causes schedule distruptions


LoadWise is highly reliable and can be adjusted to various mine characteristic and is scalable to suit any mine. It is a retro-fitted solution to suit any type of haul truck or tray.


Easy, straight-forward hardware integration and quick installation procedure. Fully vertically integrated solution with the option to choose the degree of integration and automation.

LoadWise in Action


An oversize ore blockage in the ROM (Run of mine) bin or primary crusher can typically result in downtime of between 10 – 40 minutes, if being cleared using a rock breaker. This can take significantly longer for larger rocks or instances that require manual intervention. Downtime from oversize ore blockages accounted for 4% of lost production throughout the year for a primary crusher on an iron ore mine site. The site’s capacity was 20 mtpa and ore blockages resulted in 800 ktpa of lost production. At an iron ore price of $150 per tonne, this amounted to production losses of approximately $120 million per year. The LoadWise system was demonstrated to reduce these blockages by up to 80%, and provide an increase in revenue of up to $96 million per year.

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