MMD iFMSL and ore sorting lead sustainable mining push

Fresh off the successful workshop on “Sustainable Mining through MMD’s Green Mining Solutions” in Ranchi, Subhajit Chaudhuri, Managing Director of MMD Heavy Machinery (India) Private Limited, reflects on how eco-friendly technologies like the Intelligent Fully Mobile Surge Loader (iFMSL) and Bulk Ore Sorting can play a pivotal role in achieving the Honourable Prime Minister’s Vikshit Bharat 2047 vision.

MMD Heavy Machinery (India) Private Limited held a workshop on “Sustainable Mining through MMD’s Green Mining Solutions” on May 14, 2025, at the BNR Chanakya Hotel in Ranchi. Almost 70 delegates from various PSU sectors (CMPDIL, MECON, SAIL-CET, NMDC, NTPC, etc.) and private sectors in the mining and mineral processing industries (PowerMech, Daniels) attended.

Subhajit Chaudhuri, Managing Director of MMD Heavy Machinery (India) Private Limited, believes that such an event is essential to ensure the success of the Honourable Prime Minister’s Vision of Vikshit Bharat 2047. The workshop’s major goal was to incorporate the surge loader and bulk ore sorting into the iFMSL (Intelligent Fully Mobile Surge Loader). This will combine the efficiency of the Surge Loader with the ability to consistently assay material in each truck. With known material composition, the Process Owner/Miner/Plant Operator can make processing decisions immediately at the mine face, increasing efficiency and productivity.

The way forward towards Vikshit Bharat 2047:
Subhajit Chaudhuri has urged industry leaders, mine and process owners, and many government institutions to prioritise continuous innovation, systematic adaptation, and technological advancement. The time has arrived to adopt eco-friendly crushing and conveying technology to Indian mining industries. 

Sustainable Innovations in Crushing and Conveying focused on cutting-edge advancements and best practices transforming the Traditional Mining and Mineral Processing industries. The session highlighted how the sector aligns with global sustainability goals, adopting circular economy principles and driving green initiatives. Key discussions covered energy-efficient equipment, integrating recycled materials, waste-to-resource strategies, water management in ore sorting, and the impact of automation in minimising environmental footprints. Mr. Chaudhuri was delighted that all attendees gained valuable insights into eco-friendly technologies, operational efficiencies, and regulatory frameworks shaping a more sustainable future for the industry.

The Sustainable Mining Plan integral to MMD’s Green Mining Solution supports the adaptation of emerging and Innovative Sizer technologies, which have step-change results across the entire mining and mineral processing value chain.

What is Sustainable Mining?

·         Environmental:

• Minimal impact on the Ecosystem.
• Reduction of greenhouse gases, which includes reducing carbon dioxide and NOx.
• Accurate product size and reduced fines creation compared to other size reduction technologies created a cleaner, safer working environment with fewer fines to discard.

·         Social:

• Minimal impact on local communities.
• Safety at the mine site.

·         Economic:

• Generates revenue for future generations.
• Reducing Opex but increasing productivity.

MMD’s solution delivers new performance, efficiency, and safety heights to keep our customers’ operating costs low and contribute to wider net carbon zero targets. MMD’s Semi-Mobile IPSC Solution sets an example for this.

MMD is your sustainable partner
MMD provides tailored material processing solutions and services to the mining, quarrying, and recycling industries worldwide. Its expert knowledge and proprietary technology help customers’ operations establish maximum efficiency and optimum safety and achieve their sustainability goals.

MMD prides itself on being a supplier and trusted partner, ensuring its solutions and services help with operational challenges customers face daily. From small machines processing a few tonnes per day to large mobile sizer stations producing many thousand tonnes per hour, MMD has the expertise and experience to support your project and make it a success.

Path-breaking technologies:
MMD has introduced two recent innovations to the market: the MMD Bulk Ore Sorting System and the Fully Mobile Surge Loader™. The Bulk Ore Sorter utilises cutting-edge ore analyser technology to differentiate between various grades of material at the bulk phase instead of the conventional method performed later in the processing cycle. By executing this process closer to the mine, MMD separates and disposes of waste early, saving haulage and processing costs and making operations more cost-efficient and sustainable. This approach reduces water consumption, minimises tailings volumes, and provides Semi-Autogenous Grinding (SAG) benefits, such as increased production capacity and reduced wear rates.

The Fully Mobile Surge Loader is a groundbreaking addition to the market, enhancing traditional truck-and-shovel operations to achieve up to 40 percent higher productivity. Functioning as a mobile storage bunker, the Surge Loader works along the mine face with the shovel moving continuously. The shovel deposits material into the Surge Loader without interruption until it progresses to the next stage. This continuous digging and dropping process enhances productivity while the truck fleet receives material from the Surge loader at a safe distance. The surge loader’s smoother feed into the truck decreases impact loading and truck wear, and trucks can be filled twice as quickly as with typical truck and shovel operations. Truck manoeuvres are also simpler and safer, eliminating the need to reverse the truck body into position for material drop-off. Notably, this technology is currently in use in the US.

MMD aims to integrate these two cutting-edge technologies, the Surge Loader and bulk ore sorting, into the iFMSL (intelligent Fully Mobile Surge Loader). This development would provide all of the Surge Loader’s productivity and efficiency benefits and a reliable assay of material deposited into each truck. With the material composition in each truck known, operations can be more efficient by making informed decisions on how the material should be processed directly from the mine face, where the material is more heterogeneous.

MMD Group of Companies is the world’s leading designer and manufacturer of mineral processing technologies. Private companies are dynamic and welcome change, pushing technical boundaries to become more efficient and sustainable, over 45 years of providing new solutions. There are 19 offices, sales and service centres, and six manufacturing facilities. There are almost 700 committed employees worldwide. Over 4000 devices have been installed around the world in many different sectors.

For more information, visit: https://www.mmdsizers.com/