FeedBuddy
FeedBuddy — Catch Problem Feed Before It Hurts Your Plant
FeedBuddy detects unexpected feed early, before it leads to crusher blockages, mill overloads, or kiln instability.
Think of it as a geologist who never sleeps — watching the feed 24/7 and giving early insight instead of after-the-fact explanations.
Why FeedBuddy Matters
Even well-run plants get caught off guard by sudden changes in the material coming from the mine. Most operators only realise the feed has changed after the process is already unstable:
oversized or sticky rock blocks crushers or chutes
the mill overloads when a harder ore arrives
product quality drifts and nobody knows why
the kiln becomes unstable when carbon-rich rock enters the feed
These situations feel unpredictable, but the root causes are well known.
Where the problems start
- clay or dirty rock that hangs up in crushers, chutes, or feeders
- harder, weathered, or contaminated zones that push the mill toward overload
- carbon-rich or organic seams that disrupt kiln combustion
- rapid geological changes between benches, faces, or loading points
- different reactions to feed variation across shifts
How they impact the plant
- higher rehandling and loader hours
- unstable crushers, mills, and kilns
- inconsistent product quality
- avoidable stops, clean-ups, and “mystery days”
FeedBuddy removes the guesswork by showing feed changes as they happen, before hundreds of tonnes of material create downstream problems.
Operators gain context, supervisors gain visibility, and decisions become consistent across shifts.
What FeedBuddy Does
What FeedBuddy Does
FeedBuddy uses computer vision and UV–VIS–IR reflectance spectroscopy to analyse raw feed in real time.
It provides continuous, objective monitoring of the material that drives your entire plant.
FeedBuddy:
- monitors the material stream continuously on belts and feeders
- detects contamination, grade shifts, moisture, and sticky material
- identifies zones that could cause blockages, overloads, or instability
- sends clear, actionable notifications to operators and control systems
You define the limits for your process.
FeedBuddy runs automatically in the background, providing round-the-clock monitoring with almost no operator workload.
How FeedBuddy Fits Into Your Plant
FeedBuddy integrates directly with equipment and systems already on-site:
- PLC / SCADA
- diverters, gates, feeders, chutes
- sorting and blending systems
- alarms and interlocks
Depending on your configuration, FeedBuddy can:
- divert off-spec or high-risk material
- adjust blending or feeder priorities
- raise alarms before limits are exceeded
- help prevent process-driven unplanned stops
Even without divertors or multiple stockpiles, FeedBuddy provides high value through its historical record:
- when feed changed and how severe the shift was
- which bench, face, or loading point it came from
- how feed quality trends evolve over days, weeks, and seasons
Every change is archived, letting you connect plant behaviour directly to the material that actually arrived on the belt — supporting mine planning, stockpile management, troubleshooting, and root-cause analysis.
Where FeedBuddy Is Used
FeedBuddy supports operations where feed variability influences stability, throughput, recovery, or product quality:
- Industrial minerals: limestone/lime, dolomite, gypsum, silica, feldspar, kaolin, aggregates
- Metals and bulk commodities: iron ore, nickel laterite, bauxite, phosphate
- Energy and chemical minerals: thermal coal, salt, potash
Wherever feed inconsistency creates operational risk, FeedBuddy brings predictability, control, and clarity — backed by real data.
Why Plant Managers Choose FeedBuddy
- more stable, predictable plant operation
- lower handling costs and fewer unplanned stops
- lower mining waste and higher minerals recovery
Proven in industry:
Example: At a limestone plant, FeedBuddy reduced waste-stone generation by ~40% and improved product consistency from the first day it was switched on.
This builds confidence and demonstrates immediate value.
Ready to See What FeedBuddy Can Do at Your Plant?
Let’s review your operation and identify where real-time feed monitoring can deliver the biggest impact.