SURFACE LOADING
acoustic alert so the operator can stop the machine immediately. This prevents further GET damage but also allows the lost tooth to be recovered, therefore also avoiding it reaching the crusher.“ Besides increasing safety of operations, GET DETECTION also gathers data about GET changeouts and consumption which helps to efficiently manage inventory. The next addition to the range will be the camera-based solution DIGGING VISION.”
The ecosystem is built as a modular solution, which will allow customers to opt for a combination of all three, combine two as a pair, or have each module on its own. Nostrort added that this approach ensures that every operation, regardless of size, application, or level of digital maturity can benefit from DIGGING INSIGHTS. As needs evolve, additional modules can be easily combined, expanding visibility and insight without disrupting existing workflows.
Through a centralised online portal, DIGGING INSIGHTS solutions bring all relevant information together in a single, intuitive dashboard. Key indicators, wear conditions and operations trends are displayed clearly, giving operators and managers instant visibility into what is happening.
He added that there has been a lot of interest from customers who can see the potential value from working with our technical services team, because they are analysing all the data, making key observations, and making direct recommendations.“ At MTG we look at the results and then prepare regular reports which are presented in meetings with the customer. If there are any issues, we work with them to see how we can help them improve their operations.”
Immersive Technologies- better loading starts with better training
When a mine runs multiple loading implements, Immersive Technologies says training has to reflect a simple reality- operators will work across different machine configurations so their techniques must adapt. This is especially true where operators work across machines that are of different size, different OEM or different controls configuration. Each machine behaves differently in the bank, and those differences require optimised human to machine interaction.
In simulation training, it says this is where configuration-specific features become a performance lever.“ Immersive Technologies’ SimControl software enables training scenarios to be configured by machine type, OEM make, digging setup, dipper configuration and adaptive operator-assist technologies. The overall solution flexibility supports a unified skills development pathway across the workforce while ensuring specific techniques for each loading machine are applied.”
The company says the operating error of boom jacking is a useful illustration of why operator technique must be trained deliberately.“ For example, boom jacks are often preventable by correcting common operator errors such as poor machine positioning; using excessive crowd force instead of digging upward; and making too deep / heavy a cut.”
It adds that these mistakes have a knock-on effect to mine performance in terms of stalled production; increased cycle variability; elevated downtime and repair costs; and rrosion of operator confidence under pressure
“ When this negative performance spiral occurs, the problem can be misattributed to‘ the dig-face’ or‘ material fragmentation’ or‘ the machine itself’ but the more actionable variable is how can better training reduce variance caused by the human in the machine.
One practical solution is to use Immersive Technologies SimControl software to configure training programs by machine and dipper type. For example custom configurations for the Komatsu P & H 4800XPC, 4100XPC and 2800XPC by dipper geometry( Optima vs TRC); custom configurations for OEM type- CAT ® 7495 vs Komatsu P & H 4100XPC; custom configurations based on machine size; and custom configurations based on digging setup, bench height, material, etc.
Immersive:“ The configurability of SimControl makes it easier to train operators across mixed fleet while still teaching the detail that matters in the bank: crowding approach, hoist timing, penetration control, dipper fill strategy, and clean pass execution- each tuned to the configuration.”
It says skills transfer increases when simulator capability matches what operators experience on the machine. This includes deeper support for operating techniques where technology such as Komatsu’ s Adaptive Controls are present, so training reflects the‘ real’ machine response operators will encounter under production conditions.
“ Immersive technologies simulation provides a unique advantage by enabling operators to train with Adaptive Control behaviours and different dipper configurations in simulation training. This gives training departments a practical way to build operator confidence faster, apply
Immersive Technologies simulator for Komatsu P & H 2800XPC, 4100XPC & 4800XPC electric rope shovels
the right digging technique, reduce boom jacking and align training to modern rope shovel technology in a safe, repeatable environment. The reason this is important is that the majority of simulation training for loading machines is generic and does not account accurate machines sizes, dipper geometry or technologies that interact with digging cycle.”
What about evidence? There are documented Immersive Technologies case studies of performance gains tied to technique-based training programs. This includes a South African mine achieving a 12.7 % increase in payload per hour; a Chilean mine achieving a 7 % reduction in digging cycle time; and a US mine achieving a 5 % reduction in boom jacks and a 4.9 % reduction in digging impact alarms.“ The pattern across these examples is consistent: targeted technique training plus realistic practice plus feedback loops drive measurable operational outcomes.” Immersive concludes:“ Loader performance is not only shaped by the machine, environment, or control system. It is significantly driven by the operator’ s ability to adapt technique to the conditions and the equipment in front of them. When training is built around those realities with machineand configuration-specific modules, targeted coaching, and measurable performance tracking, it improves both loading outcomes and operator development.”
The company works on a People- Process- Technology approach. The people part means building operator capability through structured learning, coaching, and on-shift reinforcement. The process refers to making the capability repeatable through clear operating standards, aligned expectations, routine debriefs, and performance follow-up. Finally the technology refers to enabling and scaling the approach through safe, repeatable simulator practice and managed services that sustain the program with support, reporting, and follow-through.
34 International Mining | MAY 2026