Molycop unveiled its latest breakthrough in real-time mill optimisation at Minería Digital 2025: a smart, sensor-driven system that delivers actionable insights to boost grinding efficiency in mineral processing operations.
Key Facts
- Molycop’s MillSlicer VIP system uses multi-sensor vibration monitoring to give operators real-time visibility of internal mill conditions.
- The innovation combines advanced instrumentation with Molycop’s proprietary AAM to prevent costly operational problems before they arise.
- Molycop’s integrated approach includes industry-tailored sensorisation, secure data modelling and hands-on technical support to maximise mill throughput and operational reliability.
The team presented a paper at Minería Digital 2025 entitled Operational mill optimisation: Real-time grinding insights through advanced instrumentation. Authored by Ignacio Molina (LATAM Technology Business Manager), Eduardo Núñez (Vice President – Process Optimisation) and Joshua Morales (Senior Process Optimisation Engineer), the paper showcased how Molycop is pioneering a smarter, more responsive approach to mill performance – one that brings real-time data, intelligent control and actionable insights together in one powerful system.
The innovation behind the paper
By using MillSlicerVIP, a multi-sensor vibration monitoring system installed directly on the mill shell and trunnions, the authors demonstrated how real-time visibility of the grinding process can unlock new levels of performance. When combined with Molycop’s proprietary Advanced Analytics Measurements (AAM), the system estimates internal mill conditions such as fill levels, liner damage and even impact trajectories – all in real-time.From detecting pegging events to optimising impact angles throughout liner wear cycles, the system enables operators to avoid inefficiencies before they become costly problems.
We spoke directly to the three authors about what drives their work and what it means for the future of mineral processing.
Ignacio Molina (4th from left) and Joshua Morales (2nd from right) at Mineria Digital 2025.
Author Q&A
What inspired the development of this real-time mill optimisation solution?
Ignacio Molina:
The inspiration comes from the entire technology team who looked at the challenges faced by the mining industry and how solutions such as MillSlicer VIP, our high-level technical support and real-time measurements are able to maximise our customers' benefits. Our technology has been in the market for over 10 years and has been efficiently validated in different mines and operating conditions.
Today, production and efficiency standards are higher than ever, and Molycop is focused on responding to industry challenges by using our developments and technologies.
How is Molycop’s technology different to other technologies in the market?
Eduardo Núñez:
There are big three pillars:- Advanced Sensorisation: The type and level of sensor technology used is specifically designed for industrial environments like AG, SAG and Ball Mills. These sensors are lightweight, safe, robust, ergonomic and easy to plug and unplug. They enable real-time monitoring of the mill’s internal dynamics, capturing detailed data at every revolution and during specific operational events.
- VIP Platform Integration: Molycop’s VIP Platform enables the modelling and deployment of MillSlicer’s unique variables alongside operational data, all while adhering to strict cybersecurity standards.
- Ongoing Support and Monitoring: Molycop provides comprehensive support – from installation and commissioning to the implementation of insights and integration with control systems – ensuring optimal efficiency, throughput and long-term performance.
What excites you most about this project?
Joshua Morales:
What excites me most is the tangible, real-world impact our technologies have. We're directly revolutionising grinding efficiency, minimising energy use and reducing wear and tear in mineral processing.Using MillSlicer VIP and AAM, we’re able to provide unprecedented, real-time insights into mill conditions.
This isn’t just theoretical – it’s a proven, deployed solution that is driving a fundamental shift in the industry. Clients often tell us that we’re challenging long-standing paradigms around traditional control strategies, which typically rely on well-known variables like bearing pressure or mill weight. These conventional indicators are often more susceptible to process disturbances, whereas our AAM provides a more stable and accurate representation of what's truly happening inside the mill.
How does Molycop’s technical package fit into its broader vision?
Ignacio Molina:
Molycop has always had a strategic and long-term perspective on the technical package services we offer. Providing continuous, real-time support with our technological solutions, such as MillSlicer VIP, is aligned with our other business lines: grinding media and chemical reagents.Plus, we’re developing synergistic and holistic solutions throughout the entire value chain of mineral processing (milling, flotation and leaching) to maximise economic and operational benefits for our clients.
