Source: ABB Global Customer Success Stories
Perth, Australia – One of Australia’s largest iron ore mining companies has reported a 30% reduction in unplanned downtime after integrating the
ABB HBFFAEAGNBA1BAA11G control module into its ore processing and conveyor systems. The implementation, completed in Q3 2024, has also improved the accuracy of ore grading by 18%, helping the site meet strict quality standards for global steel manufacturers.
Overcoming Mining’s Unique Operational Hurdles
Mining sites face a perfect storm of challenges: extreme heat, constant vibration from conveyor belts and crushers, and dust that can clog sensitive electronics. Prior to adopting the ABB HBFFAEAGNBA1BAA11G, the Australian mine relied on outdated control modules that required monthly maintenance checks and frequently failed during peak production hours.
“Our conveyor systems are the lifeline of the mine—if they stop, we can’t move ore to processing plants, and that hits our bottom line hard,” said Sarah Thompson, Operations Manager at the mining site. “The old modules would shut down when temperatures spiked above 45°C, which is common here in Western Australia. Since installing the HBFFAEAGNBA1BAA11G, we haven’t had a single temperature-related failure, and maintenance checks are now only needed every 3 months.”
How the HBFFAEAGNBA1BAA11G Delivered Tangible Results
The module’s impact was felt across three critical areas of the mine’s operations:
- Reliable Conveyor Control: The HBFFAEAGNBA1BAA11G’s vibration-resistant design kept conveyor speed consistent, reducing ore spillage by 22% and cutting cleanup time by 15 hours per week.
- Precision Ore Grading: Its high-speed data processing enabled real-time adjustments to the ore sorting system, ensuring only high-grade iron ore (with 65%+ iron content) was sent to customers—reducing rejected shipments by 18%.
- Lower Maintenance Costs: Predictive alerts allowed the maintenance team to address minor issues (like voltage fluctuations) before they became major failures, slashing maintenance costs by $120,000 in the first 3 months.
ABB’s Partnership Approach to Industrial Innovation
“Success stories like this one highlight why we design products with real-world challenges in mind,” said Mark Wilson, ABB’s Regional Sales Director for Australia and New Zealand. “The HBFFAEAGNBA1BAA11G isn’t just a control module—it’s a solution that helps our customers overcome their most pressing operational hurdles. We worked closely with the mining team to understand their needs, and the results speak for themselves.”
The mining company plans to roll out the ABB HBFFAEAGNBA1BAA11G to its other two sites in Queensland and South Australia by mid-2025. For more details on how the module supports mining and heavy-industry operations, visit ABB’s customer success portal.
