Ore to know you better: How real-time sensing tech is helping mines see smarter, waste less, and make every tonne count from pit to plant

At a time when mining operations are under growing pressure to optimise resource use, reduce waste, and demonstrate environmental stewardship, access to real-time data is no longer a luxury - it’s a necessity. Few understand this better than Marius Sugentaitis, managing partner of OreScanner, a technology company at the forefront of a shift toward sensor-based, in-line ore characterisation.

Based in Lithuania, Marius and his team have developed a system that offers something many mine managers and plant operators have long craved: the ability to “see” ore quality the moment it’s mined, crushed, or conveyed without waiting for lab results or relying on static block models. It’s this convergence of immediacy, accuracy and insight that’s giving operators a decisive edge in mine-to-mill optimisation and ESG performance.

Making the invisible visible

"Ore bodies are rarely uniform - even within a single blast,” Marius explains to The Rock Wrangler. “Yet most mines still rely on delayed lab results and static models to guide their decisions.”

OreScanner’s solution changes that by delivering instant feedback on ore grade, mineral composition, and impurities, right at the point where material is being handled - be it in the pit, at the crusher, or on the conveyor. “Our system scans raw material as it's loaded, crushed, or conveyed,” Marius explains. “There’s no need for sampling or lab delays.”

Originally designed for the industrial minerals market, OreScanner’s reach has now expanded into metals, where feed consistency and tight control over dilution are critical. Whether a site is focused on copper, iron ore or bauxite, the appeal is the same: more informed decisions, made faster.

Addressing real operational pain points

According to Marius, the challenges OreScanner is addressing are widespread and costly. These include the misrouting of high-grade ore into the waste stream, ineffective blending practices based on outdated data, and the entry of invisible impurities into processing plants. On top of that, operations lose considerable amounts of reagent and energy due to off-spec feed.

By capturing variability as it happens, rather than after the fact, OreScanner helps operations respond to changes immediately. This stands in sharp contrast to the conventional approach of relying on lab assays that arrive days - or even weeks - too late to prevent losses.

The tech behind the transformation

At the heart of OreScanner’s system is a modular, multi-sensor platform that can be tailored to suit the specific conditions and mineralogy of each site. Rather than offering a fixed solution, the technology stack is configured based on operational need.

For instance, computer vision is used to assess particle size, detect surface indicators, and identify visible contamination. Multispectral and near-infrared sensors provide mineral fingerprinting by analysing how light is absorbed and reflected by the ore. X-ray fluorescence (XRF) is deployed to determine elemental composition, while microwave and sonic sensors assess factors like moisture, density, and acoustic characteristics of the material.

This site-specific approach keeps the system scalable and focused on delivering only the data needed to support practical decision-making. “We don’t believe in a one-size-fits-all approach,” says Marius. “Instead, we match the tools to the mineralogical challenge.”

Seamless integration with mine control systems

OreScanner is designed to operate wherever material is being transferred. This includes installations at the crusher or feeder immediately after truck dumping, on conveyors for batch-wise feed control, post-crushing to optimise stockpiling or surge bin inputs, and in near-pit setups that involve mobile or relocatable crushers.

As ore passes over these transfer points, the system classifies each batch in real time - whether it’s a few tonnes or a full truckload. The material is categorised based on predefined grade thresholds, and outputs such as grade bands, contamination alerts, or routing signals are generated instantly.

These outputs can be displayed on a local dashboard, synced with cloud platforms, or integrated directly into SCADA and PLC systems via protocols like Modbus, Profibus, MQTT, or REST API. This ensures smooth integration with existing infrastructure and supports both manual decision-making and fully automated control.

Empowering real-time decisions

To support actionable outcomes, OreScanner provides users with clear, batch-level information. This includes ore grade classification into categories like premium, blend, or waste; impurity thresholds for elements such as clay, magnesium oxide, or carbon; and visual indicators such as particle size and material contamination.

Operators can set thresholds and alarms that trigger automated responses, such as material diversion or blending adjustments. This enables just-in-time alerts and decisions without the delays associated with lab-based assays or the inconsistency of visual checks.

Measurable gains across operations

While many of OreScanner’s early deployments are under non-disclosure agreements, Marius is able to share a few encouraging metrics. In some cases, sites have reduced misrouting of waste by over 30 percent. Fuel costs have also seen a notable drop - around 10 percent -primarily due to fewer rehandling cycles.

Even without adding new hardware or redesigning their flowsheets, sites have been able to improve sorting and feed consistency simply by acting on the real-time data provided by the system. “Once real-time data becomes available,” Marius notes, “sites quickly find ways to improve. It's like switching on a light in a room you’ve always walked through in the dark.”

Easy deployment, rapid ROI

One of the key design goals behind OreScanner’s Gen1 system was to create a product rather than a bespoke engineering project. As a result, installation is straightforward and requires minimal plant modification. Remote calibration is supported by the OreScanner team, and the system is compatible with existing plant hardware.

Most users see value within days of installation. In fact, some operations report that return on investment can be achieved in just a few months - especially in scenarios where misclassified feed has been a visible source of inefficiency or loss.

Looking ahead, the Gen2 version of OreScanner’s platform will incorporate more advanced spectroscopy capabilities, unlocking even deeper insights into mineral composition. While this will involve more extensive setup and reference sampling, it opens new opportunities for operations seeking higher-resolution mineralogical data.

Supporting ESG through smarter mining

For mining companies increasingly focused on their ESG obligations, OreScanner offers tangible environmental and social benefits alongside economic ones.

With less high-grade ore inadvertently lost to the waste pile, operations can extend the life of deposits and reduce strip ratios. More consistent kiln feed minimises overburn events and curbs energy consumption. The reduction in unnecessary truck movements and material rehandling lowers diesel use and associated emissions. Meanwhile, the automation of material sorting frees up personnel for more valuable work, improving safety and workforce efficiency.

“It’s not just about environmental metrics,” Marius explains. “It’s about smarter mining - fewer inputs, better outputs.”

What’s next: DilutionGuard and source traceability

OreScanner is currently piloting a new system known internally as DilutionGuard IronOre, which integrates real-time scanning with GNSS-based load tracking. This innovation will allow mine operators to match every truckload of ore to its exact source location—creating a new level of transparency and accountability in the pit.

By linking each scanned batch back to the blast pad or loading location, operators will be able to detect dilution the moment it occurs and take corrective action immediately. “The goal is simple,” Marius says. “We want to make it easier to see what’s being mined, where it came from, and whether it meets spec without waiting for the lab.”

OreScanner is actively seeking partners to participate in pilot deployments of this technology and shape its evolution.

Final thoughts

As mining grows more complex and margins become tighter, the need for better, faster, and more transparent information is paramount. OreScanner is answering that need by delivering real-time ore characterisation that supports operational efficiency, enhances recovery, and advances sustainability.

For Marius and his team, the mission is clear: empower mining professionals to make smarter decisions right now, not later.

“Real-time data is the new rock face,” he says. “If you can see what’s coming before it hits the plant, you can change the game.”