UNLOCKING MORE FROM EVERY ASSET
- Higher asset productivity improves throughput, efficiency, and cost optimisation.
- Hindustan Zinc 2.0 priorities: Maximise asset productivity (reliability-led operations and digital monitoring), cost optimisation through efficiency gains, and unlocking latent capacity (debottlenecking, process optimisation, and improved recoveries).
Asset optimisation is a key driver of sustainable and differentiated competitive advantage. We undertake structured initiatives to systematically strengthen the drive for measurable gains in equipment reliability, metal recovery, and cost efficiency, through critical asset integrity programmes, enhanced shutdown and overhaul management, advanced condition monitoring practices, and robust defect elimination frameworks. Embedded into daily operations and backed by higher employee ownership, these practices strengthen the foundation for building an AI-driven, future-ready organisation capable of unlocking new levels of operational performance and resilience.
Optimising Mining and Milling Assets
Jumbo Reliability
Maximising uptime to accelerate development
Undertook targeted midterm overhauls and strengthened scheduled maintenance across the underground and satellite workshops at Rampura Agucha Mine.
c.800 bps increase in Jumbo availability to 75%.
24% improvement in mean time between failures to 8.1 hours.
Blast Pull
Precision execution, predictable outcomes
Implemented best practices in accurate facegrid marking, parallel drilling, and effective flushing of cut holes, with a focused leadership and mine-team approach at Rampura Agucha and Zawar Mines.
4.75% improvement in blast pulls to 4 metres, aligned with development targets.
Waste Backfill
Turning waste into value
At Rampura Agucha and Sindesar Khurd mines, underground waste previously hauled to the surface is now being directly utilised as backfill material within the stopes, eliminating the need for surface transport.
Reduction in handling and hauling costs.
Reduction in diesel consumption, lowering greenhouse gas (GHG) emissions and supporting our commitment to sustainable and low-carbon mining operations.
Shaft Debottlenecking
Unlocking capacity
Undertook focused efforts to reduce the cost of hauling, through debottlenecking shaft capacity of Rampura Agucha Mine in record time with leadership driving rapid identification and execution.
Increase in hoisting capacity from 630 TPH to 660 TPH, leading to 70,000 tonnes additional shaft hoisting in FY2026.
Dilution Reduction
Precision mining for superior recovery
Undertook focused mine technical interventions in Rampura Agucha Mine under the 'zero stope failure' objective, including optimising slyping position and shoulder drill angles, adopting dome-shaped stope designs, and strengthening skin-retention practices.
20.5% reduction in overall dilution, even clocking a single-digit dilution during the year.
Improving Operational Stability Through Strategic Asset Renewal
| Optimising beneficiation | Optimising smelting | |
|---|---|---|
| Key challenge flagged by condition monitoring data | Elevated vibration levels in the ball mill. | Process parameter deviations in the roaster furnace at hydro smelter — a critical unit for refined metal output. |
| Our response | Timely, systematic, reliability-focused upgrades, including replacing the ball mill shell. | Targeted reliability-focused upgrades in the roaster furnace dome. |
| Outcome | Restored vibration levels within acceptable thresholds, enhanced asset reliability, and strengthened operational stability and predictability. | Stabilised process parameters within the defined control range, enhanced asset reliability at Rampura Agucha Mine, and strengthened downstream operational stability. |
FY2026 Asset Optimisation Outcomes
Third-party validated improvement in asset optimisation maturity, reaffirming the effectiveness of our initiatives and commitment to operational excellence.
Increase in Kaizen and small group activity, initiated with strong people involvement, enabling grassroots-led operational enhancements.