Hexagon has helped the Tokatindung gold mine revamp its material handling processes.
Efficient bulk material handling is the backbone of any successful mining operation. From the moment rock is blasted to the point it enters processing plants, every tonne must be hauled, loaded, and blended with precision. Even small inefficiencies in this chain – whether idle trucks, long queues or fuel waste – can ripple into significant losses.
At the Tokatindung gold mine in Indonesia, PT Archi Indonesia has demonstrated how digital technologies from Hexagon can transform the movement of bulk materials across the site, turning safety and efficiency into drivers of productivity.
When Tokatindung began mining operations in 2020, operators relied on manual forms of communication to coordinate trucks and material flow. This approach limited visibility and slowed down decision-making, creating bottlenecks.
Recognising the opportunity for improvement, PT Archi Indonesia partnered with Hexagon to implement OP Pro, a fleet management system designed to optimise haulage, blending, and workflow automation.
Within a year, the mine saw significant improvements in the way material moved across the site. OP Pro has since delivered a 28 per cent increase in truck productivity, reducing unnecessary delays in the handling chain and ensuring ore reaches its destination more efficiently.
“Productivity improvements were clear,” Hexagon senior manager – customer success David Prior said. “But even we were impressed by the scale of the impact.”
PT Archi Indonesia realised additional benefits such as a 16 per cent reduction in queue times, helping loaders, crushers, and stockpiles receive material faster, a four per cent reduction in hang time, ensuring trucks spend less time idle between loading and departure, and a 31 per cent reduction in fuel consumption, improving costs and environmental performance across the haulage fleet.
These results underline how intelligent fleet management and efficient bulk material handling systems are interlinked.
“I think all mining operations need it,” PT Archi Indonesia mining operation head Indra Karim said. “There’s no way we could do mining operations efficiently unless we measure it. With the fleet management system, we get real-time measurements.”
Safety remains a cornerstone of smooth material handling. By committing to protecting miners and equipment from fatigue-related incidents and accidents, PT Archi Indonesia is living up to its safety promises and avoiding disruptions that can slow material movement across the mine.
The mine, in turn, deployed Hexagon Operator Alertness System, an integrated fatigue- and distraction-management solution. This has led to significant results: fatigue-related alerts have dropped by 79 per cent, and the mine has reported zero fatigue-related safety incidents since implementation three years ago.
“The technology increases productivity, reduces operating loss, increases profitability, increases mining selectivity and, more importantly, improves safety,” PT Archi Indonesia mining group head Vinsent Agus Supriyanto said.
Beyond the technology itself, the success of these systems rests on effective change management. Solutions that optimise material flow only deliver their full value when operators trust and adopt them. That means engaging and re-engaging operators in a cycle of continuous improvement.
“At Hexagon, we don’t just install and go,” Hexagon senior consultant Arif Pratama said.
“We stay with the customer throughout their maturity journey, helping them build understanding, confidence, and trust in the technology.”
At Tokatindung, the benefits for bulk material handling are now on full display.
Production and selectivity have increased, while fuel consumption, emissions, and material losses have decreased. Every tonne is moved more safely and efficiently through the mine’s handling chain.
The result is a mining operation that not only delivers more value but also strengthens its standing in the local community.
This feature appeared in the October 2025 issue of Australian Mining.
