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Explore Cabisol

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CABISOL | Metals & Mining

From Concept to Throughput for Steel, Aluminum, and Mining Operations

CABISOL delivers integrated automation, electrification, mechanical support, and turnkey execution to stabilize high-temperature, high-load steel and aluminum operations, as well as demanding mining environments, improving line throughput, extraction efficiency, quality consistency, and energy performance.

Performance Impact

Scope includes engineered panels, instrumentation, power distribution, mechanical services, and asset-
aligned support, with Industry 4.2-aligned digital governance and analytics implemented as required.

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Throughput

Higher line output and
extraction rates

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Quality
Lower off-spec / rework

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Energy

Lower kWh per tonne

Common Pain Points in Steel, Aluminum &
Mining Operations

  • Unplanned downtime from harsh operating conditions (heat, vibration, dust, moisture)and aging electrical/automation assets

  • Throughput and quality variability due to unstable control loops, inconsistent measurements, and manual interventions

  • High energy intensity across furnaces, crushers, conveyors, drives, and utilities with limited real-time performance visibility

  • Brownfield upgrades with high cutover risk, fragmented ownership, and long stabilization cycles

  • Limited diagnostics and event correlation causing extended MTTR and repeat failures

  • Safety and environmental compliance
    challenges in hazardous and remote locations

Our Solutions

Outcome-led programs engineered to improve throughput, extraction efficiency, quality consistency, and energy performance across steel, aluminum, and mining operations.

    • EPC projects for unit upgrades and balance-of-plant modernization

    • PMC for multi-contractor execution and outage governance

    • Detailed engineering (E/A/I/M) for power, controls, and instrumentation

    • Installation & commissioning with cutover planning and SAT/FAT discipline

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    • Furnace / kiln / heat-treatment control (where applicable)

    • Rolling mill / casting line automation and interlocks (where applicable)

    • Mine automation: crusher control, conveyor systems, stockpile management

    • Hoisting systems and material handling automation

    • Industrial IoT integration and data layer for steel, aluminum & mining KPIs

    • Digital solutions, AI optimization, and digital twin (as applicable)

    • OT cybersecurity, remote monitoring and support

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    • Outage-aligned O&M models for critical assets and auxiliaries

    • AMC programs for controls, drives, panels, and instrumentation

    • Breakdown maintenance and rapid troubleshooting support

    • Calibration & testing discipline (I&C and protection verification)

    • Critical spares planning (electrical + mechanical where applicable)

    • Operator and maintenance training for repeatable operations

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    • Plant inspection and reliability audits

    • Health checks for BTG controls, drives, panels, networks

    • Energy audits focused on auxiliary power and heat-rate improvement

    • Decarbonization solutions (efficiency upgrades and roadmap support)

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    • Energy recovery & efficiency programs (auxiliary optimization and loss reduction)

    • Green energy integration readiness (hybridization interfaces where required)

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Our Products

Products deployed across the plant. Digital platforms and analytics are covered under Digital Solutions.

    • PLC control systems (controllers, remote I/O, panels, configuration)

    • DCS systems (controllers, I/O hardware, operator panels, integration)

    • SCADA and HMI (operator stations, servers, panels, configuration)

    • Industrial networking (OT-ready switches, gateways, integration as required)

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    • Flow, level, pressure and temperature instruments

    • Process analyzers (as required for boiler/utility measurement)

    • Valve positioners and control elements

    • Configuration and integration (as required)

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    • AC drives (LV/MV, panels, configuration)

    • DC drives (where required)

    • Soft starters (with panels and integration)

    • MCC panels (operation and control integration)

    • Substation equipment (as required)

    • MV switchgear (HT panels and operation)

    • LV panels (LT distribution and control)

    • Transformers (power and distribution)

    • Cables and wires

    • Protection relays and metering (configuration and integration)

    • LV motors

    • HV motors

    • Synchronous motors

    • Generators

    • Excitation/AVR and synchronization equipment

Our Support Services

  • Commissioning and cutover governance for brownfield upgrades

  • Breakdown response and troubleshooting model (asset-aligned)

  • Critical spares strategy and replenishment planning

  • Calibration/testing discipline for instrumentation and protection

  • Pre-shutdown and restart readiness support

Technical Support

  • Mechanical maintenance for crushers, conveyors, hoists, and rotating equipment

  • Equipment refurbishment and reconditioning services

  • Preventive maintenance programs for critical assets

  • Alignment, balancing, and vibration analysis support

  • Wear parts management and replacement scheduling

Mechanical Support

Our Process Expertise

End-to-end coverage across steel, aluminum process areas, mining operations, and utilities, delivered as one accountable scope.

    • Raw material handling and preparation (iron ore, coal, scrap)

    • Blast furnace / BOF / EAF control systems

    • Continuous casting lines and auxiliary systems

    • Hot rolling mills, cold rolling mills, and finishing lines

    • Pickling, galvanizing, and coating lines

    • Flow, level, pressure and temperature instruments

    • Process analyzers (as required for boiler/utility measurement)

    • Valve positioners and control elements

    • Configuration and integration (as required)

    • Crushing and grinding circuits

    • Material handling and conveyor systems

    • Hoisting and vertical transport

    • Stockpile management and reclaim systems

    • Tailings management infrastructure

    • Compressed air, cooling water, power house, and emissions interfaces

    • Grid interface, substations, and plant-wide distribution

    • Water treatment and effluent management

Digital Solutions

Digital governance and analytics that convert operations data into performance actions.

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Plant-IQ 360

Plant-IQ 360 (implemented as required): KPI dashboards for availability, heat rate, and asset health

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Remote Monitoring

Remote monitoring and support workflows for incident response

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Industrial IoT Integration

Industrial IoT integration to connect DCS/PLC, drives, meters, and analyzers

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AI Optimization

AI optimization for combustion stability and auxiliary efficiency (as applicable)

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OT Cybersecurity

OT cybersecurity solutions for hardening, monitoring, and access governance

Case Studies & Clients

  • Steel, aluminum, and mining transformation examples, tailored to plant context and confidentiality constraints.

  • Selected references and outcomes available on request (confidentiality aware)

Case Studies

View Case Studies
Request a Reference Call

Some of our esteemed clients

AL QARYAN STEEL COMPANY

DUBAI

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TATA STEEL

INDIA

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DANIELI CORUS

INDIA

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STEEL AUTHORITY OF INDIA LTD.

INDIA

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SMS SIEMAG

INDIA

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PAUL WURTH INDIA PVT LTD

INDIA

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JINDAL STEEL AND POWER LTD

INDIA

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HULAS STEEL INDUSTRIES LIMITED

NEPAL

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Concept to Commissioning

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