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GullySystem
Water and Environment · Software for mineral processing companies

Follow every tonne from the run-of-mine pad to the concentrate shipment.

A mineral processing plant turns ore into concentrate, and the money sits in the gap between the grade fed and the grade shipped. The software holds ore receipts, stockpile blocks, mill shifts, reagent use, assays and dispatches in one record per lot, so recovery can be read after each shift.

At a glance

Ore arrives from one or more pits and goes onto stockpiles by grade. The crusher, the mills and the flotation or leach circuit then turn it into a concentrate that a smelter or trader pays for by assay. Weights, moisture and assays decide the invoice. Small errors cost real money.

Plant software for mineral processing ties the feed tonnes to the assay results and to the concentrate that leaves the gate. A first workshop can follow one stockpile block from the pad through the circuit to the shipping bag, and mark the step where grade and tonnes part ways. Gaps show early.

How the work runs today

Trucks bring ore to the run-of-mine pad and cross the weighbridge. The receiving clerk notes the source pit, the haul ticket and the block, and the grade controller tips the load onto a stockpile. A front-end loader then feeds the crusher on a blend plan, and a belt weigher counts the tonnes that actually enter the plant.

Each shift the operators log mill throughput, cyclone pressure, reagent dosing and tank levels. The sampler cuts a composite from the feed, the concentrate and the tailings. The laboratory assays them and reports back. Then the plant waits. Concentrate is bagged or loaded in bulk, weighed out and shipped with a sampling certificate that names the lot, the moisture and the sample split. Settlement follows the umpire assay. Disputes wait for it.

Where it breaks

What goes wrong for mineral processing companies without a proper system.

Feed tonnes and assays sit apart

The weighbridge ticket is in one file and the feed assay is in the laboratory system. Nobody can multiply tonnes by grade for a single stockpile block without retyping.

Recovery is worked out weeks late

A metallurgist rebuilds the mass balance from shift sheets after month end. By then the mill has run a different blend for days and the cause of a low recovery is gone.

Reagent use cannot be tied to a shift

Collector, frother and lime are drawn from the store in drums. The consumption per tonne milled is a guess because the drum issue and the mill log are never read together.

Liners and mill parts wear out unnoticed

Mill liners, pump impellers and screen decks are changed when something fails. The hours run since the last change are in a maintenance planner’s head.

Concentrate shipments differ from the contract

The buyer’s weight, moisture and assay come back different from yours. Without the sample split record and the lot history, the dispute is a matter of whose paper is trusted.

What the software does

What we would build for mineral processing companies.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Ore receipt and stockpile blocks

Record each truck at the weighbridge with its source pit and haul ticket, and hold stockpile balances by block and grade for the blend plan.

Mill shift log

Operators enter feed rate, grind size, cyclone pressure, dosing and downtime by circuit, so a shift report builds itself from what was logged.

Sample register and assays

Track each composite from the sampler to the laboratory, with the assay result tied to the feed, concentrate or tailings lot it came from.

Metallurgical balance

Combine feed tonnes, assays and concentrate weights into recovery and mass balance by shift, day and lot. Gaps are flagged for review.

Reagent and consumables store

Issue collectors, frothers, lime and grinding media against a circuit and a shift, then read use per tonne milled.

Wear parts and maintenance

Hold running hours for mills, pumps, screens and conveyors, with planned liner changes and work orders raised from them.

Concentrate dispatch

Build each shipment lot with bag or bulk weights, moisture, sampling certificate and buyer reference, and keep the umpire assay that settles it.

Before you talk to a supplier

A requirements checklist for mineral processing companies.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready product

A product already built for mineral processing companies.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Mineral Processing Company Management Software

Ore receipt, stockpile blocks, mill shift logs, sample and assay register, reagent store, wear parts and concentrate dispatch for mineral processing plants.

See the product
Solutions inside

The business modules mineral processing companies use most.

Each one is also available on its own, or inside a system built for you.

How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Common questions

Questions mineral processing companies ask before they call.

Does it connect to the weighbridge and the belt weigher?

Typed entry works for each ticket, and an export from the weighbridge indicator can be imported in bulk. Live belt weigher readings need a link built and quoted after the site is surveyed.

Can it work out recovery for a flotation circuit?

Yes, from the tonnes and assays you record. The formulae your metallurgist already uses are entered and checked against a past month before you rely on them.

We run a leach plant, not flotation. Is that covered?

Yes. Stages, tanks and reagents are named the way your plant runs them, so cyanide or acid circuits are recorded as their own steps and not forced into a flotation layout.

How are laboratory results brought in?

The laboratory can enter results in the screen, or send a results file from its instrument system. The choice follows whatever the laboratory runs today, and we confirm it with the lab team at the first workshop.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

Share your requirements