New Tricks for an Old Trade: Technology and the Future of Minerals Processing
8/14/2026
You can’t teach an old dog new tricks. Or can you?
As in many industries, technology is transforming the way we work. Operations and maintenance in minerals processing today are not the same as they were five years ago, and they will certainly not be the same in another five years. The industry must adapt, and so must the people doing the work.
One new ‘tech of the trade’ is AI-driven predictive maintenance, a key Industry 4.0 technology. PwC’s global AI performance study found that mining scored the lowest of any sector on its AI fitness index, while the most AI-fit companies in any sector saw performance gains 7.2 times higher than their peers. And this is only one of the new technologies now at our fingertips.
To build a future-ready mining industry and keep up with global players, service providers and mine operators have no choice but to adapt and become future-proof.
For this reason, EXMINCO is hiring engineers with a future mindset and investing in the latest technologies, combining fresh insights and innovation with the wisdom gained from decades of industry experience. Together, this creates a robust foundation to meet the operations and maintenance needs of both today and tomorrow.
Meet one of our new dogs
One of our latest recruits, Engineer Louis van Rooyen, has already started implementing systems and technologies that are having a significant impact on operations, only a couple of months in. As Louis puts it: “I tend to approach a plant as an interconnected system rather than as a collection of individual machines.” Louis continues that this allows him a holistic view, focusing not only on the equipment that has failed, but also on the process conditions, operating practices, maintenance history, available data, and the people interacting with the plant every day.
In addition to Louis’ differentiated approach to operations and maintenance, he also emphasised that his generation has a significant advantage due to access to tools that were not always available in the past, including real-time data, condition monitoring, digital modelling, and advanced analytical software. In his words: “The value of these tools is not simply in producing more information, but in using that information to identify trends, anticipate problems, and make better-informed decisions before failures occur.”
While the latest technology is critical, years of experience and time spent on site remain major advantages for EXMINCO. As Louis puts it:
“Technology cannot replace practical experience, sound engineering judgement, or genuine engagement with the people on the plant. For me, a forward-thinking approach means combining modern tools with established engineering principles and learning from the experience of those who have worked in the industry for many years.”
Gerhard Hendriksz, EXMINCO’s Managing Director, and by his own admission, not above learning a new trick or two, agrees, and sees it firsthand. As he puts it: “With AI becoming increasingly competitive in optimising processes, Louis has mastered the AI concept in ways I had never imagined, utilising it to pave the way for EXMINCO to become a leader in future O&M service offerings.”
The old dog behind it all (with all due respect)
That experience behind Gerhard’s words is backed by more than 40 years in the field. And it is also the reason why clients turn to EXMINCO to operate and maintain their minerals processing operations.
Gerhard has walked into enough struggling operations to know how quickly things can spiral: systems go down, spares become unavailable, artisans get overworked, and negativity starts to creep in as the operations team misses its targets and blame begins to circulate. Left unmanaged, this spreads like a veld fire. Sometimes, the right move is to step back and regroup rather than push through. Gerhard sums up his philosophy simply: 90% planning, 10% execution. Many operators go wrong by chasing their tails trying to catch up, and rarely succeed. It’s better to take the knock and re-plan than to keep pushing.
When asked why clients turn to EXMINCO for operations and maintenance solutions, Gerhard’s answer was simply:
“It is our FIRST approach, with Focus on the client’s business, Integrity in how the business is approached, taking Responsibility for the operation without neglecting Safety standards, and by applying the latest Technology and industry standards.”
Gerhard added that it might sound obvious, but this FIRST acronym, when lived with purpose every day and kept top of mind for every task, is the reason behind EXMINCO’s success. It’s also why our clients can focus on the strategy and growth of their business while EXMINCO manages the day-to-day operations. That peace of mind is what our clients get as part of the contract.
Old dogs, new dogs, one direction
So, what does EXMINCO’s future-proof model promise to bring to operations and maintenance?
Our clients can rest assured that EXMINCO is fully equipped for the future of mining. Gerhard brings both deep technical knowledge and well-honed interpersonal skills from years spent on plants, understanding what customers truly need to achieve throughput targets. He also recognises that embracing new technology is imperative to keep operations moving forward and meet the demands of a rapidly evolving industry.
With ore bodies becoming increasingly difficult to extract and project terms shortening as ore deposits grow smaller, the new industry knowledge that next-generation engineers like Louis bring means the future of operations and maintenance is becoming brighter.
Driving Operational Excellence with Next-Generation Technologies
Clients rely on EXMINCO’s Enterprise Asset Management platform, a live system built on accurate asset registers with barcode capability, criticality and functionality analysis, and work planning and control for resource allocation. This platform supports preventative maintenance by identifying potential issues before they disrupt operations.
The Verge Production Management platform integrates with SCADA/PLC systems, either directly or via Historian, to capture and analyse downtime data. This feeds a data warehouse for business intelligence reporting and real-time dashboards.
Condition Monitoring and 3D scanning are two of the newer capabilities in EXMINCO’s offering, already adding measurable value for asset owners and continuously refined as part of our commitment to continuous improvement. With Condition Monitoring, critical plant equipment is observed in real time, allowing developing issues to be identified and addressed before they escalate into costly breakdowns. Additionally, 3D scanning provides precise, engineering-grade digital models of assets, even when original documentation is unavailable. This technology replaces slow, error-prone manual measurement with validated models that can be confidently provided to fabricators or refurbishment teams, ensuring both accuracy and efficiency.
A partner now. A partner for the future.
We all know the future is uncertain; no one can predict it. But with partnerships built on trust, the latest technologies at hand, and a forward-thinking approach, we can only look ahead with enthusiasm for what is to come.
Even if old dogs need to learn new tricks.
Source: PwC (2026) Mine 2026: Ambition to Action.