Balancing safety, productivity and profitability has always been a “defining challenge” in deep-level mining, but the mining stope – the core of underground operations – has long remained invisible to decision-makers because of the absence of reliable, real-time data, says StopeSense operations manager Willem Schoeman.

Although conventional monitoring tools and fragmented instrumentation solutions were tried in the past, most could not withstand the demanding underground environment, he says.

As a result, equipment would fail, maintenance was complex and without dedicated technical support, such systems became unsustainable, explains Schoeman.

“The effort to maintain these systems outweighed the perceived benefits, and the resulting data was often unreliable or simply not collected.”

The dynamic nature of underground mine stoping also poses unique challenges, with conditions constantly changing; therefore, monitoring approaches must be continuously adapted to remain effective, he explains.

Consequently, the company has developed a comprehensive solution that combines installation, monitoring and execution in one streamlined process.

Refined over more than ten years of research and development, and tested at several mines across South Africa, Schoeman says the StopeSense system delivers accurate, real-time information on critical stope and mining parameters at an affordable cost.

This approach enhances decision-making, supports digital transformation and, ultimately, improves operational efficiency and sustainability.

“The StopeSense service brings together metering equipment, communication, data management, execution and reporting into a single turnkey offering. Gone are the days when multiple vendors and systems were needed to create a workable solution. This is a true ‘one-stop shop’,” says Schoeman.

Different from Competitors

What sets StopeSense apart is its data-to-value service model, states Schoeman, adding that the company views data as an asset that must be actively managed, not simply collected and stored.

To ensure that value is extracted from every data point, the company maintains a 24/7 control room and a dedicated data management team. On-site execution engineers work alongside stoping crews to maintain systems, interpret results and identify opportunities for performance improvement.



During its development, the system was subjected to an 18-month test phase, during which the test also produced measurable financial and operational benefits.

Schoeman says yearly cost savings of about R1.5-million to R3.5-million were achieved in energy cost reductions on compressed air and water consumption per cross-cut, adding that these savings were possible because previously unmonitored services could now be tracked and optimised.

Beyond utility management, the solution measures production parameters such as scraper winch cleaning patterns, blast confirmation and environmental conditions.

“These measurements directly support safer and more consistent production cycles. They also help boost operational resilience by identifying inefficiencies and safety risks before they escalate,” notes Schoeman.

The resulting insights show potential to improve shift productivity, contributing up to R8-million in additional value per cross cut.



To overcome the high upfront costs typically associated with advanced monitoring technology, Schoeman says that StopeSense adopts a distinctive business services model.