MOBi

Molycop’s cutting-edge Online Ball Tracking system, MOBi, forms the backbone of Molycop’s Grinding Media Management Plan. By monitoring grinding media from delivery, bunker scanning and in-mill charge monitoring through to scats analytics, MOBi empowers mineral processing operations to run smarter, safer and more efficiently.

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Features

  • LiDAR-powered bunker scanning delivers real-time inventory visibility and automated reorder alerts
  • Continuous monitoring of silo/bin weights for precise consumption tracking
  • Full end-to-end tracking of grinding media from bunker to mill
  • Automatically records crane location, bucket movement and mill charging activity
  • Uses MillSlicer sensors and adaptive machine learning models to measure charge dynamics
  • Predicts wear rates and charge requirements, integrating directly with inventory planning
  • Reconciles additions, scats and wear loss to provide true cost and performance insights

Overview

MOBi, Molycop’s cutting-edge Online Ball Tracking system, transforms the way mining operations manage grinding media. More than just a tracking tool, MOBi forms part of Molycop’s comprehensive Grinding Media Management Plan – covering the journey of grinding media from the bunker into the mill.

By combining precise inventory control, real-time crane and bucket distribution tracking, and in-mill charge monitoring, MOBi ensures that Molycop grinding media reaches the right place at the right time – eliminating inefficiencies, preventing shortages and maximising throughput across mineral processing operations worldwide.

The challenge

Managing grinding media is complex:
  • Traceability: Usually involves human intervention and manual processes.
  • Inventory inaccuracy: Visual or manual bunker stock checks lead to shortages or over-ordering of supply.
  • Sub-optimal mill charge: Overloading wastes energy, underloading reduces throughput.
  • Steel scats losses: Scats accumulate unpredictably, distorting wear and performance data.
  • Performance inefficiency: Traditional manual methods – bucket logging, visual checks and operator ‘feel’ – are no longer enough for today’s high-performance operations.

The MOBi solution

MOBi addresses these challenges with an end-to-end digital solution, providing full visibility and control of grinding media flow:

1. Enhanced inventory control
  • Bunker scanner integration: LiDAR-powered scanning provides continuous bunker volume and mass data, delivering real-time inventory tracking and automated reorder alerts.
  • Smart bin load cells: Continuous monitoring of silo/bin weight ensures precise consumption measurement.
  • Digital traceability: Every delivery can be tracked from bunker to mill.
2. Real-time crane and distribution tracking
  • Real-time tracking: Tracks crane location, bucket movements and mill charging activity automatically.
  • Removes errors: Eliminates manual logging errors, even during night shifts.
  • Eliminates inefficiencies: Ensures the right media load goes into the right mill, every time.
3. Advanced in-mill charge measurement
  • MillSlicer and sensor technology: Monitors impact signatures and charge dynamics in real time.
  • Dynamic charge estimation: Adaptive machine learning (ML) models adjust for liner changes, ore variability and wear.
  • VIP ball charge analyser: Predicts wear rates and charge requirements, directly linked to inventory planning.
4. Scats management and ball-balance analytics
  • Automated scats traps with Vision QC: AI models classify broken versus intact balls, providing real-time feedback on wear performance.
  • Ball-balance calculations: Tracks true wear loss by reconciling additions, intact scats and broken-ball mass.
  • Predictive insights: Identifies brittle batches or process upsets early, reducing losses.

Typical Uses

MOBi is used by mining operators to track and manage grinding media with precision, from bunker inventory through to in-mill charge monitoring. By combining machine vision, real-time data and intelligent forecasting, it helps optimise resource use, reduce waste and maintain consistent material flow across the milling process. 

Benefits

  • Full traceability: From bunker to the mill.
  • Optimised energy usage: Maintains ideal charge levels to maximise throughput and grinding efficiency.
  • Reduced downtime: Automates reordering and bunker scanning to eliminate stockouts and manual checks.
  • Accurate wear accounting: Real-time reconciliation of media additions versus scats for cost control.
  • Data-driven decisions: Dashboards deliver insights for procurement, process optimisation and maintenance.
  • Regulatory compliance: Digital audit trail supports environmental and quality reporting.

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