How Digital Twins and Smart Tech Are Reinventing Battery and Mining Operations
By Stephen Breen, Lead Architect at ZeroMission
From the pit to the plant floor, a digital transformation is underway, quietly reshaping how we mine materials and manufacture the batteries that will power the EV future.
At ZeroMission, we’re seeing more industries, particularly mining and battery manufacturing, embrace tools like digital twins, manufacturing execution systems (MES), and AI not just to optimise performance, but to future-proof operations. The common thread? Data-driven, connected systems that turn complexity into clarity.
Mining Smarter, Not Harder
In modern mining projects, digital twin software is quickly becoming standard. And it’s easy to see why. These virtual replicas of mine operations are doing more than just simulating processes, they’re enhancing equipment designs, accelerating commissioning, and improving workforce training.
But there’s a challenge. Despite integrating cutting-edge innovations, many mines still face fragmentation. Systems are deployed in silos, requiring staff to juggle multiple platforms with limited interoperability. That’s where digital twins, combined with unified control platforms, offer more than visibility, they offer cohesion. By integrating power, control, and information systems, mines can reduce the learning curve and vastly improve maintainability and operational uptime.
The goal? One ecosystem. One interface. Real-time insights that drive real-world decisions.
Manufacturing That Keeps Up with EV Demand
On the manufacturing side, especially in gigafactories, the biggest roadblock isn’t just scaling, it’s quality.
Battery production can see scrap rates exceeding 10%, a figure unthinkable in traditional automotive lines. If battery supply is going to keep pace with soaring EV demand, that has to change.
Enter the MES. A robust manufacturing execution system links plant-floor data with business systems. It gives battery manufacturers a granular view of their operations, detecting anomalies, managing defects in real time, and benchmarking performance across shifts, products, or even entire plants.
Pair this with AI-powered CT scanning, and you have an incredibly powerful feedback loop. Internal battery defects are detected in real time, fed back into the MES, and used to automatically adjust upstream processes. It’s AI talking to AI, solving problems before they multiply.
From Conveyor Belts to Intelligent Conveyance
It’s not just the cells that need refining, every step in the production line matters.
Many battery makers are now turning to intelligent conveyance systems to increase throughput by up to 40%. Unlike traditional mechanical conveyors, these systems use magnetic motion to move products quickly and precisely. No wear parts. Less maintenance. Faster speeds. Greater precision.
What’s more, they allow for inline inspections at high speed, ensuring only high-quality batteries continue down the line, while issues are immediately routed for further inspection or rework.
The Real Competitive Edge: Integration
This is where the real opportunity lies: not in isolated upgrades, but in integrating everything, across mines, plants, supply chains. Digital twins, MES platforms, AI inspections, smart transport, all speaking the same language.
When data flows freely between systems, decision-making gets sharper. Scrap rates fall. Uptime rises. And manufacturers gain the agility needed to handle surging demand while navigating global supply chain challenges.
Powering the EV Future Starts Now
EV adoption isn’t slowing down, and battery makers, miners, and manufacturers need every advantage to stay ahead.
Whether it’s smarter mining, faster commissioning, or scrap-slashing quality control, one thing is clear: the future belongs to those who can connect, optimise, and evolve faster than the challenges coming down the line.
At ZeroMission, we’re helping organisations do just that, with integrated platforms built for the realities of modern operations.
Let’s make the complex simple and power the future, together.
