FRAGTrack™ Gen 4

The challenge was to evolve FRAGTrack™ from a proven fragmentation measurement tool into a future-ready, scalable platform that could serve a wider range of mining applications globally. The system needed to withstand extreme environments – dust, vibration, water, impact and temperatures from -40°C to +60°C – while becoming easier to install, service and adapt. Importantly, this expansion in capability had to be achieved without increasing complexity for operators, maintainers or installers, and while reinforcing Orica’s leadership in digital mining through a coherent, globally resolved industrial design.

FRAGTrack™ Gen 4 was developed through close collaboration between Design Anthology, Orica Digital Solutions and Syndetic, guided by real-world operational insight from global mine sites. The solution centres on disciplined simplification: a compact, modular hardware architecture that improves reliability, serviceability and manufacturability while supporting multiple deployment scenarios. Iterative prototyping, environmental testing and stakeholder validation ensured the design performs in harsh conditions and integrates seamlessly with Orica’s digital ecosystem, resulting in a robust, scalable platform that is easier to deploy, maintain and evolve over time.

FRAGTrack™ Gen 4 delivers impact across operational, commercial and environmental dimensions. It reduces installation and maintenance effort, extends service intervals and enables broader deployment of fragmentation intelligence across mine sites globally. By preserving accurate, georeferenced measurement at critical points in the mining process, the system supports improved blast design, reduced downtime, higher throughput and more efficient downstream processing – strengthening Orica’s digital offering while enabling safer, more resilient and more productive operations.

FRAGTrack™ Gen 4 is a rugged, modular machine-vision platform designed for extreme mining environments. Its compact, industrially refined form communicates precision and durability while supporting efficient global shipping and installation. A unified core architecture supports multiple deployment configurations including mobile digging equipment such as excavators, front-end loaders and face shovels as well as fixed plant installations, through interchangeable lenses and mounting solutions tailored to site needs. The system captures high-density 2D and 3D imagery to generate particle size distributions from individual rock measurements. A unique, patented capability allows each image to be geolocated in three-dimensional space with ±1 m accuracy, enabling fragmentation data to be linked upstream to blasting and downstream to routing, stockpiling and processing decisions. Design priorities included plug-and-play connectivity, intuitive servicing access, reduced dirt traps and IP67 sealing to maintain optical clarity and reliability. Developed through extensive testing and validation, FRAGTrack™ Gen 4 balances durability, ease of use and scalability while integrating natively with Orica Digital Solutions’ platforms such as BlastIQ™ as well as third-party fleet management systems.