South American Surface Mine

Transforming Fleet Efficiency & Emissions Reduction in Open-Pit Mining

How a Major South American Operation Achieved Massive Fuel Savings and CO₂ Reductions with Cascadia Scientific
Cascadia Scientific

Decision intelligence that drives optimized mining operations.

Case Study Summary

In response to rising fuel costs, operational inefficiencies, and growing sustainability pressure, one of South America’s largest open-pit coal mines partnered with Cascadia Scientific to deploy AI-driven fleet optimization tools across its operations.
Through machine learning, real-time coaching, and predictive analytics, the operation:

The Challenge:

This operation faced mounting challenges: high diesel consumption, inconsistent operator behavior, reactive maintenance practices, and rising demands for carbon transparency and performance improvement.

The Cascadia Scientific Solution

Cascadia Scientific deployed its SmartRView platform and Machine Learning Coach tools across a multi-OEM fleet that included over 250 assets. The solution delivered:

Since 2023, this partnership has delivered more than 10.1 million liters of fuel savings and over 27,500 tonnes of CO₂ reductions, driven not by any one solution, but through a holistic strategy combining truck-level analytics, operator coaching, and road condition optimization.

“Cascadia became an extension of our operations team. They didn’t just deliver data; they guided decisions that delivered results.”
— Operations Manager

Operational Impact

49 preventative maintenance referrals, 811 operators flagged for training, and 97 improvements made to haul roads
Truck Intelligence
  • ML models identified abnormal fuel usage
  • Example: One unit improved -1.25 gal/hourpost-maintenance intervention
Operator Coaching
  • Personalized feedback led to rapid performance shifts:
  • Operator 1: -0.68 gal/h
  • Operator 2: -0.62 gal/h
Haul Road Improvements
  • 97 road segments repaired or regraded
  • Key zones improved by 3–1.5 gal/passin fuel use
Environmental Impact
  • 8,100+ tonnes of CO₂ avoided in 2023
  • 19,400+ tonnes of CO₂ avoided in 2024
  • Contributes to corporate Scope 1 emissions goals
  • Enables detailed, auditable ESG reporting
“These results reflect a joint commitment between Cascadia and our engineering teams — driving measurable savings through precision interventions and real-time insights.”
— Site Engineering Lead

Scalable Transformation

Cascadia Scientific turned fleet-wide fuel efficiency and emissions reduction into a repeatable, scalable strategy that drives both financial and environmental results.

Metric
Before
After
Change

Fuel per Pass

2.52gal

1.00gal

-1.52 gal

Vibration

High

Reduced

Reduced Vibration

Braking Behaviour

Excessive

Normal

Improved Operator Performance

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A Model for Scalable Mine Optimization

This project’s success is a direct result of strong collaboration, dedicated effort, and hands-on action from the local team. Like any data-driven solution, achieving full value depends on active involvement and follow-through at the site level. We’re proud of what’s been accomplished together and excited to see what more we can achieve as this partnership grows

Ready to Turn Data Into Measurable ROI?

If you’re looking for:

Then it’s time to move beyond dashboards—and into action.

Let’s explore how Cascadia can help your mine realize measurable, lasting impact.