Production efficiency in quarries is largely determined by the effectiveness and quality of blasting operations, which represent the first and one of the most strategic stages of aggregate production. The outcome of blasting defines the particle size distribution of the material, directly influencing the performance and total cost of downstream crushing and screening processes, including the overall energy intensity of the processing line.
Improper fragmentation—whether too coarse or excessively fine—disrupts the balance of the entire technological process. Oversized material reduces crusher throughput and requires additional processing, while excessive fragmentation leads to high explosive consumption, often exceeding the energy savings achieved in subsequent stages.
Challenges in balancing blasting and processing costs
A key aspect of production management is maintaining an optimal balance between blasting costs and downstream material processing costs. This requires continuous monitoring of blasting quality and in-depth analysis of the relationship between fragmentation level, production efficiency and plant energy consumption.
Modern quarries therefore face the challenge not only of selecting appropriate blasting parameters, but also of integrating data from different stages of production. In the era of mining digitalisation, the ability to consolidate and interpret process data is becoming essential to better understand complex technological interactions and precisely control fragmentation.
Blasting operations – the importance of parameters for material quality
The blasting process requires precise selection of multiple technical parameters, including the type and quantity of explosives, hole pattern density and geometry, and the initiation method. Each of these factors affects rock breakage and the final structure of the blasted material.
Insufficient explosive charge leads to oversized boulders that significantly reduce crushing efficiency and generate above-average operating costs. Excessive blasting intensity improves fragmentation but results in disproportionately high explosive consumption. Optimisation therefore lies in selecting parameters that minimise total blasting costs and downstream unit energy consumption of crushing—not just one of these elements.
Photo analysis and particle size distribution curves as production control tools
Photo analysis enables detailed assessment of blasting results through analysis of images captured immediately after blasting. Image processing algorithms generate particle size distribution curves, showing the percentage share of individual size fractions and their compliance with technological requirements.
The particle size distribution curve is one of the most important quality control tools, allowing rapid identification of fragmentation deviations, assessment of blasting stability, and adjustment of parameters for subsequent blasts. This enables active quality management before the material enters the processing line.
Integrating TMS data – analysing efficiency and unit energy consumption
TMS is an advanced system for monitoring operational processes in quarries. Sensors installed on haul trucks and weighing systems record transported material mass, haul cycle time and energy consumption, enabling calculation of unit energy consumption (kWh/t).
Combining TMS data with photo analysis and particle size distribution results provides a complete picture of how blasting quality affects downstream production stages. Analyses clearly show that poorer fragmentation (larger average particle size) reduces crusher performance and increases energy demand. Conversely, very good fragmentation—achieved at the cost of higher explosive consumption—reduces energy intensity but increases blasting costs.
Data integration makes it possible to identify the optimal compromise point, i.e. a set of parameters that minimises total production costs.
Cost optimisation in quarries
From an economic efficiency perspective, it is essential to consider two main cost groups simultaneously:
- blasting costs, dependent on explosive selection and blast design parameters,
- electricity costs resulting from crushing and screening processes.
Only a combined analysis enables informed management of fragmentation and production efficiency. Integrating photo analysis and operational data within TMS allows multi-dimensional analyses, identification of minimum unit costs and definition of operating parameters tailored to deposit characteristics.
Location and efficiency – spatial data utilisation in TMS
Extending TMS with spatial data functionality enables tracking material origin down to the loading location. Correlating fragmentation quality with specific locations makes it possible to assess geological variability and its impact on blasting effectiveness and overall process energy consumption.
Such analyses support production planning that accounts for local geological conditions, enabling more precise control of blasting operations and improved efficiency across the entire production chain.
TMS as a strategic tool for aggregate production and quality optimisation
Advanced integration of photo analysis data, particle size distribution curves and operational parameters collected by TMS enables systematic management of aggregate production through:
- precise planning and adjustment of blasting parameters,
- optimisation of electricity consumption in subsequent process stages,
- maximisation of crusher throughput,
- maintaining stable and repeatable material quality.
As a result, TMS goes beyond being a logistics tool and becomes a strategic system for quality and efficiency control, supporting technical and economic decision-making that directly impacts the competitiveness of the entire operation.