Hindustan Zinc plans Rs 2,000 crore AI value push

What Hindustan Zinc announced

Hindustan Zinc Ltd (HZL), a Vedanta Group company, has outlined a plan to generate Rs 2,000 crore in value by rolling out artificial intelligence-driven solutions across its mining and manufacturing operations. The company positioned the move as part of a broader shift toward AI, automation and industrial intelligence in heavy industry and metals and mining. It said platforms such as V-Spark are intended to support the next phase of smart manufacturing transformation.

V-Spark and the startup-led innovation pipeline

Hindustan Zinc said it is working with over 50 deep tech startups on more than 100 projects through V-Spark DeepTech Ventures. The company described the focus areas as production enhancement, cost optimisation, value creation, ESG leadership, asset performance, safety and operational efficiency. Separately, it also said that through Vedanta Spark, the Vedanta Group’s corporate accelerator programme, Hindustan Zinc is engaging with over 20 technology startups on 50-plus innovation projects.

Digital mining and automation: the tools being deployed

In its digital mining roadmap, Hindustan Zinc highlighted tele-remote technology, AI and robotics, and smart sensors to enhance operations. It also pointed to data-driven decision making through AI, machine learning and real-time dashboards, aimed at pattern analysis, resource planning and improved uptime. The company said it is accelerating deployment of these solutions across mines and manufacturing units as part of its smart mining plan.

Fleet intelligence system powered by IIoT

Hindustan Zinc said it is deploying a fleet intelligence system powered by the Industrial Internet of Things (IIoT). The initiative is designed to improve operational reliability, energy efficiency and predictive maintenance across its heavy earth-moving machinery (HEMM) fleet. The company described this as a milestone in its smart mining roadmap.

Collaboration Centre as a central digital command hub

At the centre of the programme is Hindustan Zinc’s Collaboration Centre, described as a central digital command hub. The company said it aggregates data from plant systems, sensors and fleet-level IIoT devices to deliver real-time visibility and analytics for faster operational decisions. It added that the fleet-level IIoT devices were developed in partnership with Machine Max, a Vedanta Spark startup.

Automation examples already implemented

Hindustan Zinc said it has introduced an AI-powered camera surveillance system that reduced manual intervention by nearly 50%. It also said the surveillance deployment enhanced operational efficiency by 20-30% while supporting workplace safety and compliance monitoring. The company further cited robotic automation in high-temperature smelting operations to improve precision and safety, and said it is set to deploy LiDAR-enabled drone-based stope scanning to strengthen underground mine mapping and extraction planning.

Debari smelter: AI-enabled switchyard hotspot monitoring

In Udaipur, Hindustan Zinc said it has implemented an AI-enabled Switchyard Hotspot Monitoring System at its Debari smelter in Rajasthan, which it described as the world’s oldest zinc smelter. The system provides real-time detection of electrical up and downs, automated WhatsApp and tiered email alerts, and dual access through on-premises and cloud platforms. The company said the solution is expected to convert unplanned shutdowns into planned maintenance, enhancing uptime and improving production efficiency.

Reported impact: outage elimination and reduced losses

Hindustan Zinc said the Debari monitoring application was developed with Vedanta Spark and startup partner Ripik.AI, with enhancements incorporated based on trial feedback. It said the system reduced total production losses by nearly 20% through 100% elimination of unplanned outages. The company said the solution is accessible via cloud deployment as well as in the Electrical SCADA (Supervisory Control And Data Acquisition) Room to enable faster response by operational teams. It added that the technology is planned for scale-up across its Mines and Smelters switchyards, Rectifiers and Flexible Busbars.

AI tool to optimise chemical dosing across smelters

Hindustan Zinc also announced an AI-powered automation tool that uses AI and machine learning recommendation models to optimise dosing of key consumables such as zinc dust, sodium sulphate, lime and cement. The company said the system was trained on historical data to support predictive and adaptive process optimisation while maintaining consistent output quality. It said the solution integrates data from Laboratory Information Management System (LIMS), Distributed Control Systems (DCS) and Programmable Logic Controllers (PLCs). The company said the transformation spans three major smelting units: Chanderiya Smelting Complex in Chittorgarh, Dariba Smelting Complex in Rajsamand, and Zinc Smelter Debari in Udaipur.

Sustainability, safety and logistics themes in the programme

Hindustan Zinc also referenced green logistics, water treatment plants and increased use of renewable energy to reduce carbon impact. On safety and workforce enablement, it cited AI-enabled wearables, real-time personnel tracking, and AR/VR training. It also described a digital-first logistics management platform intended to transform procurement and delivery of metals.

Key facts at a glance

What it means for investors and operations

The company’s disclosures focus on measurable operating outcomes such as reduced manual intervention, improved uptime, and lower production losses, rather than near-term financial guidance. For a metals producer, initiatives linked to predictive maintenance, energy efficiency and process control can directly affect production stability and cost optimisation, and Hindustan Zinc has tied multiple deployments to these outcomes. The company also framed the rollout as part of a broader effort to scale AI-enabled monitoring and automation across units in Rajasthan.

Company commentary

Hindustan Zinc’s CEO Arun Misra said the switchyard and rectifier hotspot monitoring application is another step toward more optimised operations, adding that digital innovation is central to shaping the future of metals and mining. He said AI-driven monitoring and predictive systems are intended to improve production efficiency while building a foundation for scalable, tech-first operations across units in Rajasthan.

Conclusion

Hindustan Zinc is expanding AI, IIoT and automation across mining, smelting, monitoring and logistics, backed by partnerships through V-Spark and Vedanta Spark. The company has reported specific operational improvements from deployed systems and has said the Debari monitoring solution will be scaled to additional switchyard and rectifier infrastructure across its network.