Metal, Mining & Cement

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Automation in the Mining, Metal and Cement Industries

Competitive production costs are one of the major issues metal-, mining- and cement-based manufacturers are facing as more and more advancements in these products come to market. System enhancements can improve your margins, but only if you avoid setbacks associated with overtaxed resources, schedule slippage and false project estimates. Whether you are in need of automation in mining industry, automation in the cement industry, or automation in the metal processing industry, our experts are here to help. Malisko can help you manage your risk by deploying robust automation and information systems always with an eye on your bottom line.

Applications for Cement, Metal and Mining Automation

Bag Houses
Booster Pumps
Brine Tanks
Bulk Packaging
Calcination-Burning Raw Material to Clinker
Cement Mills
Cement Silo Storage Tanks
Clarifier Pumps
Clinker Storage Tanks
Coal Mills
Cross Belt Analyzers
Crushing and Compacting
Drying and Screening
Dust Pumps
Filtering and Drying
Finish Mills
Flocculant (Optiflox Systems) and Coagulant Systems
Limestone Silos and Conveyance
Liquid MgCl2 Tank Storage
Load Sharing
Main Loadout Silos
Material Cooling
Packaging and Palletizing
Pond Systems
Primary and Secondary Additive Silos
Pulverized Coal
Pumping Stations
Purification Washing Stations
Raw Material Crushers
Raw Mill Homogenization
Semi and Train Car Loadout
Sizing and Packaging
Slurry Thickening
Solar Evaporation
Storage and Pre-homogenization of Raw Materials
Sulfate and Color Removal
Wash Plants

News Release: Major Metals Manufacturer Chooses Malisko for OT Network Design

Malisko Engineering, Inc. has been retained to provide Engineering Services for three primary OT Networks at a major metal manufacturer in the US.

Case Study: Cement Manufacturer Incorporates Cross Belt Analyzer, Optimized Control to Improve Quality and Consistency

A client wanted to increase product consistency and quality while also reducing material clean-up time and downtime due to corrective maintenance.

Case Study: Cement Manufacturer Upgrades OT Server Platform to Increase Uptime

Malisko was tasked with the OT platform replacement while keeping production interruption at an absolute minimum.

Case Study: Industrial Network Upgrade Lays IIoT Groundwork for Leading Minerals Producer

A global minerals producer wanted to implement IIoT at one of their U.S. facilities, and knew they needed help as they were already encountering limitations within the existing networking infrastructure.

Our Approach to Automation in the Mining, Metal and Cement Industries

No two plants are the same. No two production processes are either. We deliver an automated production process that works for you. And it will work as perfectly as physically possible. Whether you’ve already implemented some automation, just finished an OEE review, or are starting from the beginning, we’ll provide the service you need. We can provide a business justification for process automation, design your automated system, or implement a system that’s already been designed. We can do it all and jump in at any point during the process.

Our approach to process engineering and automation has delivered results for over 20 years. It has allowed us to provide our clients with consistent, efficient production, and measurable ROI. How do we do it?

Site Assessment

Before we can design your new system and implement automation solutions that save you money and improve efficiency, we have to understand your challenges. To achieve this, we can engage with you to perform a site assessment. We listen to your operators, maintenance staff, engineers and operations personnel to fully understand your process, how your business operates, the problems you want to solve and what success means to you. Most important, we take the time to understand the best ways to collaborate with your in-house engineers throughout the automation process as we become familiar with your facility and the systems that make it run.

Our site assessment follows a tried and true process and is the first step in implementing an automation solution. During each site assessment, we will:

  • Identify Existing Automation Controls
  • Identify Potential Cost-Saving Solutions
  • Identify Opportunities
  • Business Justification
  • Presenting Automation Solutions
Front-End Engineering Design (FEED)

Successful engineering has to align everyday production with the big picture. Each processing unit and work cell must come together with your automation system to form not only an efficient production process but also one that matches your business goals and realities. When we present an automation solution to you, we make sure it matches your budget, your timeline, your current production realities and your goals, all while minimizing risk.

Our Front End Engineering Design (FEED) sets the foundation for a successful project accomplished on time, on budget and in a way that fits your in-house team.

If the needs of your business, plant and production line change over time, our systems come ready to change along with them. And if you need, we’ll even tweak the system design to fit the skill sets of your support team. We believe the best systems change for you. It shouldn’t be the other way around.

Once the FEED is completed, you will receive:

  • Outlined Business Objectives
  • Project Timeline & Budget
Detailed Engineering and Design

In our detailed engineering and design service, we transform the conceptual into the final design. We use all the knowledge we gain from the automation solutions site assessment and Front End Engineering Design (FEED) to minimize your risk, get you running quickly, and align our work with your business realities. Here we will also flush out project risks, planning for them by nailing down a realistic project budget, execution plan and timeline.

Malisko both designs your automation system and implements it. Our detailed engineering and design service picks up right after our FEED services leave off, and our system integration execution picks up right after our detailed engineering and design. We can handle the complete package: specification, design, procurement, development, on-site execution, troubleshooting and support of the control, network, security and MES layers.

During this phase, we can provide you with:

Project Execution

After we’ve completed our thorough automation solutions site assessment, Front End Engineering Design and Detailed Engineering Design, we have the information we need to document, code and integrate your automated system. We keep in mind your business goals. We factor in the strengths and limitations of your team, and we prioritize your most important objectives.

We design your system on a foundation of understanding so that we can rapidly implement it with absolute precision. We program each function in your system and set up an intuitive Human Machine Interface (HMI) and reporting that allows your team to adopt your system efficiently. We outfit your system with the reporting you need to stay on top of your production. Prior to installation, we run your system through several rounds of intensive testing in a simulated environment to make sure it works. Once we have programmed your machines, set up your HMI, created a useful reporting program and tested the functionality and performance of your system, it is time to install your system in your facility. When on-site system installation is complete, our team again extensively tests the operation, performance and functionality of the new system holistically from the field devices through to reporting.

During this phase, we can provide you with:

  • Programming & Logic Development
  • Human Machine Interface (HMI) Development
  • Reporting
  • System Integration Testing & Simulation
  • On-Site Process Commissioning

Computer System Validation (CSV) is a must in FDA-regulated industries. We design and implement your system to deliver consistent, efficient production that also meets CSV for FDA. And we prove it too. If you operate in a regulated industry, we take care of the paperwork related to CSV and reduce your Regulatory risk. We can provide a Validation Master Plan (VMP) and use it to guide our work. We document requirement specs, design specs, functional specs, test plans, installation and operational protocols, trace matrices and summary reports. We execute the protocols as well. We assist with keeping your records up-to-date via change control and help keep your system in compliance. Minimizing risk is ingrained in our company because we are committed to delivering you ROI.

During this phase, we can provide you with:

  • Computer System Validation Documentation
  • Executed Validation Protocols
  • Electronic Records
Post Project Support

If any troubles emerge with your system, we have you covered, whether it is warranty or support under a formal service contract. When you work with Malisko Engineering, you don’t just get a system, you get a whole team to support it. If you have a full maintenance and system support staff on hand, we will provide assistance to fill the cracks. As much as practical, we can help your team be properly equipped to maintain and troubleshoot your process and automation system. If you need full support services, we are available 24/7 to make sure your system works.

During this phase, we can provide you with:

  • Post-Commissioning Technical Support
  • Remote Support

Why Hire a Systems Integrator?

Can’t decide between a systems integrator and a general contractor for plant automation? Learn how systems integrators save you money, add value and ensure quality. Download our White Paper to learn more.

Metal-, Mining- and Cement-based Manufacturers Need Automation

Enlist automation services that are backed by decades of proven results. Contact Malisko’s experts today.

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