Loading smarter not harder: How precision payload data is delivering more tonnes with fewer cycles in modern open pit mining

In open-pit mining, some of the biggest productivity gains can come not from buying more trucks, but from loading the ones you have with greater precision.

In open-pit mining, productivity gains often require major capital investment - bigger trucks, additional shovels, or new haul road infrastructure. But Jarym Kowalchuk, Head of Product, Operations and Autonomy at Hexagon’s Mining division, argues that some of the biggest wins are hiding in plain sight.

“Optimising payload is one of the most common goals across open-pit operations,” Jarym told The Rock Wrangler. “In truck-and-shovel mines where payload is weight-limited rather than volume-limited, improving loading accuracy can deliver a 5–10 percent increase in average payload per truck - often without any investment in new or additional equipment. For operators, this is essentially ‘free tonnes’.”

The trick is achieving those gains without triggering a spike in overloads, which carry risks ranging from slower cycles and extra fuel burn to equipment damage and safety incidents. That’s where precision load optimisation - driven by real-time data - is changing the game.

Closing the gap between guesswork and precision

In traditional operations, shovel operators have often relied on experience and a degree of guesswork to load trucks to target weight. Without instant, accurate feedback, even the most skilled operators face a trade-off: leave tonnes in the pit by underloading, or risk costly overloads.

Hexagon addresses that challenge with a low-latency, peer-to-peer (P2P) communication link between shovel and truck, enabled by its OP Pro platform. This allows bucket-by-bucket payload updates to be sent directly to the operator in real time - without relying solely on the mine’s operational network.

“Without a reliable, low-latency connection, operators either get no payload update at all, or the data arrives too late to adjust before the next bucket,” Jarym explains. “In that case, it’s effectively useless. With OP Pro, they see both the current load and the tonnes remaining to hit the target, so every bucket counts.”

This precision transforms payload management into a repeatable, measurable process - one that works even in network ‘black spots’ where conventional fleet management systems can lag or drop out entirely.

More than payload: a data highway in the pit

While payload data is the headline application, Hexagon’s P2P link is a versatile communications channel. The same connection can carry mine control messages, production updates, or even new task assignments straight to the operator.

“Machines can share critical information without depending entirely on the broader mine network,” Jarym says. “That means operators stay connected and informed, and cycles stay efficient.”

By decoupling key machine-to-machine interactions from central network infrastructure, OP Pro effectively creates a localised, high-speed data highway inside the pit - a major advantage for sites with patchy coverage or demanding topography.

Automation and AI: reducing operator workload

Payload optimisation doesn’t just rely on better data - it also depends on presenting that data in a way that fits the flow of work in the cab.

“Through sensor fusion and real-time data sharing, we let operators focus on running their equipment with minimal manual interaction,” Jarym says. “The system automatically detects when a truck has started loading, establishes a link to the shovel, and begins presenting live updates through an intuitive interface.”

Hexagon also draws on its experience applying artificial intelligence in other parts of the mining value chain, including safety systems and its Drill Assist solution. Where AI can improve decision-making speed or consistency, those capabilities are integrated into the payload management environment.

From data overload to insight

Mining fleets generate vast amounts of data. Fleet management systems and asset health platforms continuously record hundreds of measurement points per second, from payload weights to component temperatures, cycle times, and engine diagnostics. Without the right analytics, this flood of data can overwhelm rather than inform.

Hexagon tackles the challenge in three ways:

• Clear, actionable reporting – Through its Fleet Analytics and Asset Health reporting suites, Hexagon distils raw data into KPIs that operations teams can act on immediately.
• Data integration – Inputs from multiple onboard systems are combined, creating insights that wouldn’t be possible from a single data source.
• Advanced analytics and AI – Machine learning models help predict maintenance needs and identify productivity opportunities before they become urgent issues.

“It’s about making sure the right people see the right information at the right time,” Jarym says. “That’s how you turn data into value.”

Integration without boundaries

Interoperability remains a priority for mine operators who run mixed fleets or rely on multiple OEM systems.

“Hexagon’s OP Pro and Machine Guidance systems include onboard and database interfaces that third-party solutions can access,” Jarym explains. “Our Fleet Management System and Asset Health platforms already integrate OEM equipment data, consolidating it into a single dataset for unified reporting and analysis.”

That flexibility allows mines to build payload optimisation into existing operational workflows without being locked into a single vendor ecosystem.

Beyond productivity: the safety and compliance dividend

While the productivity case for precision payload management is compelling, the safety and compliance benefits are equally significant.

Overloaded trucks face increased risks: reduced braking and steering performance, compromised stability, and greater susceptibility to structural fatigue.

“Consistently meeting compliance targets - with verifiable data - also supports warranty claims and regulatory requirements,” Jarym notes. “It’s about keeping both the machines and the people operating them safe.”

Avoiding overloads also has a clear mechanical benefit. Key truck components such as suspensions, frames, and braking systems experience less stress, extending service life and reducing unplanned downtime.

Fuel efficiency and sustainability

While “free tonnes” may be an informal term, the efficiency gains are very real. By hitting target loads more consistently, operators can move the same volume with fewer truck cycles. That means lower fuel consumption per tonne and reduced greenhouse gas emissions.

From a sustainability perspective, these savings contribute directly to corporate ESG targets. Fewer cycles also mean fewer total operating hours - a benefit for both maintenance schedules and workforce exposure to operational hazards.

A glimpse ahead

Hexagon isn’t standing still. According to Jarym, the company is actively testing new features within its payload management systems aimed at unlocking further efficiency, safety, and sustainability benefits.

“We expect to share more on these developments in 2026,” he says, hinting at innovations that may further integrate payload optimisation into the broader automation and analytics ecosystem.

Changing the culture of loading

Perhaps the most important impact of precision payload technology is cultural. By giving operators accurate, real-time feedback, the system encourages a more disciplined, target-driven approach to loading - one that can be tracked, measured, and continuously improved.

In an industry where seconds per cycle and tonnes per hour add up to millions in annual value, the shift from guesswork to precision is more than a technical upgrade. It’s a mindset change - one that blends operator skill with the best of modern mining technology.

“Ultimately,” Jarym says, “we’re giving operators the tools to do their job better and giving management the confidence that every truck is running at its optimal load. That’s good for productivity, for safety, and for the bottom line.”