- At Debari, Rajasthan, Hindustan Zinc introduces an AI-enabled monitoring solution for switchyard and rectifier hotspots, ensuring early anomaly detection and tier-wise alerts.
Udaipur, 25th September, 2025: Hindustan Zinc Limited (BSE: 500188 & NSE: HINDZINC), India’s only and the world’s largest integrated zinc producer and one of the top 5 silver producers globally has rolled out an AI-powered Switchyard Hotspot Monitoring System at its Debari smelter the world’s oldest zinc smelter in Rajasthan to boost equipment reliability and operational efficiency. The solution delivers real-time detection of electrical fluctuations, automated WhatsApp and tiered email alerts, and dual access via on-premises and cloud platforms. By transforming unplanned shutdowns into planned maintenance, the system is designed to improve uptime and enhance production efficiency.
Developed jointly by Hindustan Zinc, Vedanta Spark and startup partner Ripik.AI (an applied AI company developing computer vision agents, based out of Gurugram), the application incorporates extensive feedback and enhancement requests received during its trial phase. By enabling early issue detection and prompt intervention, this solution has significantly reduced total production losses by nearly 20% through 100% elimination of unplanned outages.
With seamless accessibility through cloud deployment as well as in the Electrical SCADA (Supervisory Control And Data Acquisition) Room, the system ensures operational teams can respond instantly to potential inefficiencies. This marks a key milestone in Hindustan Zinc’s broader initiative to deploy AI-powered monitoring and automation solutions across its operations, further maximising asset utilisation. Technology is planned for scale-up across Hindustan Zinc’s Mines & Smelters switchyards, Rectifiers & Flexible Busbars.
Commenting on the development, Hindustan Zinc’s CEO – Arun Misra said: “The Switchyard & Rectifier Hotspot Monitoring Application is another step forward in our journey towards more optimized operations. At Hindustan Zinc, we believe digital innovation is key to shaping the future of metals and mining. By embedding innovative AI-driven monitoring and technology-led predictive systems, we are not only increasing production efficiency but also solidifying the foundation for scalable, tech-first operations across all our units in Rajasthan.”
Hindustan Zinc continues to drive innovation in the metals & mining sector by deploying advanced technologies that enhance safety, efficiency, and sustainability. The company collaborates with startups in key areas including production enhancement, cost optimization, value creation, ESG (environmental, social & governance) leadership, and improved safety practices. At present, Hindustan Zinc is working with over 40 technology startups on more than 60 projects through Vedanta Spark—Vedanta’s global corporate accelerator and ventures program. Vedanta Spark partners with innovative startups to tackle critical business challenges using emerging technologies, driving large-scale transformative impact. Through Vedanta Spark, Hindustan Zinc has tapped into high-impact opportunities by harnessing technologies like Artificial Intelligence/Machine Learning, computer vision, drone solutions, the Internet of Things (IoT), and Augmented/Virtual Reality (AR/VR).
Furthermore, Hindustan Zinc has established a first-of-its-kind digital collaboration centre that analyses data from all business units and provides real-time insights for robust decision-making process. Hindustan Zinc has also embedded technological excellence and innovation such as robotics, artificial intelligence, blockchain, and the Industrial Internet of Things (IIoT), across its operations., Recently the company announced the implementation of an advanced AI – powered camera surveillance system, across its operations. This innovative solution ensures workplace safety, operational efficiency and compliance monitoring. By integrating this technology, Hindustan Zinc has enhanced operational efficiency by 20-30% while significantly reducing the need for manual intervention by nearly 50%. Additionally, the company has deployed robotic automation in smelting operations, boosting precision, streamlining metallurgical workflows, and ensuring consistent product quality. Through these innovations, Hindustan Zinc is redefining the future of mining in India and setting new global benchmarks for the indus
About Hindustan Zinc Limited
Hindustan Zinc Limited (BSE: 500188 and NSE: HINDZINC), a Vedanta Group company, is the world’s largest integrated zinc producer and is amongst the top 5 silver producers globally. The company supplies to more than 40 countries and holds a market share of about 77% of the primary zinc market in India. Hindustan Zinc has been recognized as the world’s most sustainable company in the metals and mining category for the second consecutive year by the S&P Global Corporate Sustainability Assessment 2024, reflecting its operational excellence, innovation, and leading ESG practices. The company also launched EcoZen, Asia's first low carbon 'green' zinc brand. Produced using renewable energy, EcoZen has a carbon footprint of less than 1 tonne of carbon equivalent per tonne of zinc produced, about 75% lower than the global average. Hindustan Zinc is also a certified 3.32 times Water-Positive company and is committed to achieving Net Zero emissions by 2050 or sooner. Transforming the lives of 2.3 million people through its focused social welfare initiatives, Hindustan Zinc is among the Top 10 CSR companies in India. As an energy transition metals company, Hindustan Zinc is pivotal in providing critical metals essential for a sustainable future.
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For any media queries, please contact:
Ms. Maitreyee Sankhla
Head - Corporate Communications
Hindustan Zinc Ltd
HZLCommunications@vedanta.co.in
