Automating Routine Laboratory Processes for Efficiency & Operational Excellence

You might wonder what separates a good mining laboratory from an exceptional one. The answer isn’t just about having the latest equipment or the fastest turnaround times. True operational excellence delivers results with unwavering integrity, reproducibility, and confidence. Let’s examine the facts about automating routine laboratory processes. Discover how you can improve your mining lab’s efficiency while maintaining rigorous standards.

What Does Operational Excellence Mean in a Mining Lab?

Operational excellence is about trust in your data and results beyond speed or output volumes.

As ELS Technical Director Dave Harvey says, “Operational excellence means producing data with integrity and confidence.”

Your data must reflect the true nature of each sample. This guides responsible mining decisions that affect both profitability and environmental stewardship.

Every manual step introduces variability. Reducing human error is crucial for achieving consistent and reliable outcomes. This is where automating routine laboratory processes offers a clear advantage.

Why Automation is Essential for Mining Lab Efficiency

Understanding the role of automation will enable you to make informed decisions about your laboratory’s future. Automation delivers three fundamental benefits that manual processes cannot match consistently.

• Reduced Variability: Eliminates manual inconsistencies between operators and shifts, leading to more reliable results.
• Standardised Results: Automation delivers reproducible outcomes, essential for compliance and traceability.
• Higher Throughput: Automated systems increase capacity and reduce turnaround time, which is key in fast-paced mining environments.

Which Lab Processes Should Be Automated First?

You don’t need to automate everything at once. Prioritise high-impact, labour-intensive areas first.

Sample preparation should lead your efforts. Drying, crushing, and pulverising introduce variability. “Automating sample prep removes the biggest risk: the human element,” says Harvey.

XRF and fusion presentations are also prime candidates. Conveyors and sample changers reduce handling while maintaining integrity.

Add-ons like precision dosing systems, Rotary Sample Dividers (RSDs), and automatic flux weighing systems streamline repetitive tasks. Namely, sub-sampling, reagent addition, and flux preparation, freeing up technician time for higher-value work.

Robotic Versus Linear Automation: Which Approach Suits Your Lab?

This choice often determines the success and sustainability of your project. Let’s examine both approaches.

Robotic Automation uses robotic arms to handle samples. These systems are precise but complex and costly. They’re ideal for large labs with technical support teams and generous budgets.

Linear Automation relies on conveyors or buckets to move samples through each stage. This method is more accessible, cost-effective, and scalable for most mining labs.

Linear automation has proven effective in several mining labs across Africa. These systems typically include:

• Crushers
• Automated feeders
• Conveyors
• Dosing systems
• Rotary Sample Dividers (RSDs)
• Sample changers

All of which are arranged in a smart, sequential flow. This modular setup reduces manual handling while maintaining consistency and high throughput. Thus, they are ideal for labs looking to boost efficiency without investing in full robotics.

Lab Design Considerations for Automation

Your facility must support the equipment and processes involved in automating routine laboratory processes. Consider these key design factors:

• Space Requirements: Automated equipment demands more floor area. It often requires reinforced flooring to handle vibration and weight loads.

• Infrastructure Needs: Plan for false floors, compressed air lines, and network cabling. PROFIBUS systems enable equipment communication.

• Environmental Controls: Temperature-sensitive components require stable conditions to function reliably.

• Safety Systems: Robotic setups must include safety locks and emergency stops to protect workers and equipment.

Common Automation Mistakes to Avoid

You’ll want to sidestep these frequent misconceptions.

Wrong skill assumptions:

Technicians, rather than chemists, typically operate and maintain automated systems. These professionals handle the mechanical, electrical, and process aspects of automation, working with equipment like sample changers, dosing systems, and pellet presses. Chemists are necessary for QAQC checking.

Overestimating savings:

Don’t believe automation reduces headcount significantly. Technical support and maintenance staff remain essential for optimal system performance.

Ignoring infrastructure needs:

Avoid underestimating infrastructure costs and space requirements. These “hidden” expenses can substantially impact your project budget.

How ELS Supports Your Lab Automation Journey

At ELS, we guide laboratories in automating routine laboratory processes through considered planning and purpose-built layouts. We provide equipment essential for semi-automated workflows:

• Cone crushers with automated feed
• Rotary Sample Dividers (RSDs)
• Sample changers
• Fusion systems for XRF, ICP and AA digestions
• Dosing systems, sieve shakers and automatic weighing systems
• Semi-automated fire assay tools, including mechanised furnace loaders and crucible handling systems.

We help you implement the optimal combination of tools for a high return on investment. This works even without full robotics.

Whether you’re working with a small sample volume or managing a high-throughput lab, we tailor each solution to your budget, available space, and analytical goals.

Key Challenges and Lessons Learned

Some challenges require hybrid approaches. Wet sample drying, for example, benefits from semi-automated systems with human oversight.

Structural upgrades often prove necessary to support equipment vibration and weight requirements. Factor these costs into your planning from the outset.

Technical support is vital. Even the best systems require trained personnel for maintenance and optimisation.

Smaller operations may benefit more from partial automation. It’s flexible, scalable, and offers excellent value.

These lessons help ensure smoother implementation, avoid costly downtime, and accelerate your lab’s return on investment.

The Future of Laboratory Automation

“The lab of the future will be lean, automated, and AI-driven,” predicts Harvey. But full automation isn’t always necessary—or viable.

Expect lean teams managing smart systems with AI-enabled quality control and predictive maintenance. Paperless operation through LIMS and barcode tracking will be standard.

Modular systems will dominate. Labs will automate fusion, digestion, and preparation without massive capital outlay.

At ELS, we’re witnessing the future unfold. There has been a marked shift toward modular fusion systems and automated sample changers in mining labs across Africa.

Similarly, fire assay workflows are moving toward semi-automated flux dosing and mechanised crucible handling to boost accuracy and reduce technician fatigue.

Sample preparation remains the biggest opportunity for efficiency gains.

Your Next Steps

“Automation doesn’t start with robots. It starts with smart layout and the right tools,” emphasises Harvey.

Start with your bottlenecks. Focus on areas where manual labour introduces delays or inconsistencies.

For example, begin with sample preparation workflow, implement strategic automation where it delivers maximum impact, and build upon success with additional automated systems. This technique can help you achieve operational excellence.

Understanding these principles will inform your decisions when creating a more efficient, reliable, and profitable operation that serves your mining objectives with precision and confidence.

Book a lab assessment or consultation with our technical team. We’ll help identify what can be automated for the best return.