Metso continues to expand its leadership in digital capabilities within the minerals processing sector, now reporting that its fleet of connected equipment has surpassed 800 active units. This figure has more than doubled since the introduction of the company’s Data-driven Performance Services in September 2025. By leveraging these digital tools, customers receive measurable enhancements in maintenance efficiency, workplace safety, and overall productivity, while successfully preventing costly equipment failure.
Enhancing Operations with Data-Driven Performance Services
The integration of connected equipment provides rapid insights and actionable steps through Metso’s Data-driven Performance Services. According to Arttu-Matti Matinlauri, Vice President of Minerals Digital at Metso, utilizing these systems yields a high rate of failure prevention, successfully identifying 80 to 90 percent of potential issues. Matinlauri notes that customers have observed availability increases of up to six percent, alongside a reduction in carbon dioxide emissions by as much as 20 percent per tonne.
This deep level of analysis is achieved by combining standard instrumentation, advanced analytics, and artificial intelligence models with specialized equipment failure modes and effects analysis (FMEA). Experienced personnel at dedicated Performance Centres further support this process. Consequently, the practical application of these technologies mitigates unplanned downtime. By identifying developing issues early, operators can proactively plan corrective actions, lowering operational risks and boosting the reliability of minerals processing output. The company can now holistically evaluate both individual assets and complete process islands.
Measurable Value from Operational Data in South America
A real-world application at a customer site in South America highlights the tangible benefits of linking connected equipment with Metso’s Data-driven Performance Services. The site reported a sustained decrease in unplanned downtime and an increase in operational reliability, demonstrated by an extended mean time between failures. These results were driven by proactive condition monitoring and well-timed field interventions.
During the initial six months of implementation, the system detected 94 percent of identified risks, allowing the site to mitigate problems early. This proactive approach avoided over 215 hours of potential downtime and decreased the necessity for replacement parts. Ultimately, the site captured 7.4 million dollars in total value.
Pablo Zuniga, Director of Performance Services at Metso, notes that these outcomes illustrate how their solutions improve customer operations and support their ambition to stay at the forefront of the industry. Zuniga emphasizes the ongoing commitment to working alongside clients, turning operational data into concrete, measurable value. Harvesting and utilizing this operational data remains central to delivering tangible results.