In mining, owing to the inherently finite and complex nature of mineral deposits, margins tend to decline. Bankable gains often come from “invisible” improvements: tighter process control, fewer interruptions and better use of existing assets, says process measurement equipment supplier Mecosa.

One of the strongest and most overlooked levers is accurate, continuous slurry density measurement in hydro-transport and material-transfer lines. Berthold Technologies has quietly established itself as a hidden champion in efficiency using radiometric measurement to translate better control into measurable savings,” says Mecosa, which is the sole agent for Berthold in Southern Africa.

It describes slurry density as the “operating truth of a pipeline” because it reflects solids concentration, water balance and the flow behaviour that drives pump load and wear.

“When density drifts, costs rise fast. Too low and you pump excess water, wasting energy and reducing solids throughput. Too high and you increase abrasion risk or even worse you move closer to unstable flow or blockages. Consistent density control also supports downstream circuits, especially flotation and separation, by delivering a steadier feed that helps operators hold the plant at its optimum.”

Mecosa points out that Berthold’s system measures without coming into contact with the process.

“A gamma source and a detector are mounted externally on opposite sides of the pipe; the detector measures transmitted radiation, which changes with the density of the medium inside. Because both components sit outside the pipe, the measurement is completely contactless – well suited to abrasive, corrosive slurries, and extreme mining environments. Installation is typically clamp-on, mostly without pipe modification.”

Mecosa notes that contact-based sensors can suffer from erosion and moving-part wear, frequent recalibration, and maintenance outages. Berthold avoids this as it has no moving parts.

Further, a key differentiator in the field is “empty-pipe behaviour”, with Mecosa explaining that many technologies fail or require recalibration after pipes run empty, while Berthold detectors are engineered to handle empty-pipe events and high count rates without performance degradation or recalibration.

The Savings Breakdown

Mecosa explains that precise density control in flotation and separation can raise throughput by 3% to 10% and improve mineral recovery by 1% to 5%, equating to a yearly gain of between roughly $500 000 to $5-million, depending on operation size and value chain.

Moreover, enhanced process control can reduce the pump’s energy consumption by up to 15%, translating to potential savings of about $500 000/y. “For mines managing tight power budgets, this is a direct margin win.”

Berthold notes that unplanned downtime owing to sensor failures can cost up to $500 000/h. Mecosa says that Berthold’s high-reliability measurement helps prevent the cascade of stoppages that follow poor signals or failures. With no moving parts and minimal wear, Berthold estimates maintenance savings up to $50 000/y per unit, compared with mechanical or contact-based systems.

A Practical Example

In a hydro-transport line feeding a concentrator, operators want the highest solids loading that remains stable and pumpable.

“If density is underestimated, water is added ‘just in case,’ reducing solids moved per hour and increasing energy per tonne. If density is overestimated, the line approaches its stability limit, increasing the probability of pressure spikes, accelerated wear, or blockages. With continuous, external density measurement, the control loop can hold the solids concentration in the sweet spot, maximising mass transfer while protecting pumps and pipes. The same signal supports early warning for developing blockages and improves performance across slurry transport, tailings/thickeners, and separation circuits.”

Meanwhile, because the measurement is independent of many changing physical properties of the slurry and the hardware sits outside the pipe, it remains reliable where abrasive solids, corrosion and temperature swings can defeat conventional instruments. The system delivers online, real-time information, and its high sensitivity supports strong results even with low source activities thereby helping mines minimise operating effort while keeping measurement quality high.

Berthold highlights typical payback periods of six to 18 months and long-term return of investment of 300% to 1 000% over five years. The system is designed for a life of between ten and 15 years, quite often without any recalibration.

“Berthold’s edge is not only the physics of radiometric measurement – it is mining-ready execution: external clamp-on installation, rugged contactless operation, long-term stability, and resilience to empty-pipe events.”

Backed by a worldwide service network, Berthold provides measurement solutions for mining that span density, level, bulk flow, and moisture, comments Mecosa, which will be exhibiting at Electra Mining Africa 2026.

Hall 4 Stand K04