Mipac Releases New Guide to Control System Upgrades for Brownfield Plants

In the rapidly evolving mining industry, control system upgrades represent a critical yet challenging aspect of operational maintenance. Addressing this need, Australian engineering firm Mipac has released a comprehensive resource titled “A Guide to Control System Upgrades,” aimed specifically at operations leaders in mineral processing plants.

The guide addresses the complex reality of modernizing aging control systems while maintaining operational integrity. Mining operations worldwide face increasing pressure to update legacy systems without compromising safety protocols, production targets, or financial constraints—a balancing act that has become increasingly difficult as digital transformation accelerates across the sector.

“Our clients aren’t just upgrading technology; they’re managing risk in high-stakes environments,” explained Eddie De Rivera, Mipac’s Managing Director. “This guide distils decades of brownfield experience into practical steps that operations teams can apply immediately.”

Industry experts have long identified several persistent challenges in control system modernization projects. Among the most common are incomplete or outdated documentation, obsolete hardware that lacks manufacturer support, increasingly narrow maintenance shutdown windows, and growing cybersecurity threats. The Mipac guide offers targeted strategies for addressing each of these obstacles.

The timing of this publication is particularly relevant as mining operations worldwide grapple with digital transformation initiatives. According to recent industry analyses, approximately 65% of control systems in mining operations are approaching or have exceeded their recommended operational lifespan, creating both safety and efficiency concerns.

Control systems—which manage everything from crusher operations to leaching processes and tailings management—form the operational backbone of modern mining facilities. Failures or vulnerabilities in these systems can result in costly downtime, with estimates suggesting that unplanned outages can cost major mining operations between $80,000 and $1 million per hour depending on the facility size and commodity prices.

The guide joins Mipac’s growing library of technical resources for mining professionals. Previous publications have addressed specific operational challenges in flotation circuits, leaching operations, and smelter performance—all critical processes in mineral extraction and processing.

Mining technology analysts note that the industry has historically been conservative in adopting new control technologies, often maintaining systems well beyond recommended lifecycles. This cautious approach, while understandable given the high-risk environment, has created a significant backlog of necessary upgrades across the sector.

The comprehensive nature of Mipac’s guide reflects the multifaceted challenges of modern control system projects. Beyond the technical aspects of hardware and software implementation, successful upgrades must address knowledge transfer, staff training, and change management—elements that are often overlooked in planning phases.

Cybersecurity has emerged as a particularly urgent concern for mining operations. As control systems become more interconnected and digitally integrated, they present potential vulnerabilities that were non-existent in older, isolated systems. The Australian Cyber Security Centre reported a 13% increase in cyber incidents affecting critical infrastructure sectors, including mining, in the past year alone.

For mining operations considering control system upgrades, the guide offers a structured approach to project planning that encompasses risk assessment, scope definition, contractor selection, and implementation strategies. This systematic methodology aims to reduce project failures, which industry surveys suggest affect nearly 40% of major control system initiatives.

The guide is available for download directly from Mipac’s resource center and represents part of a broader industry trend toward knowledge sharing and standardization of best practices in mining technology implementation.