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As we’ve seen before, in open-pit mining operations, diesel accounts for an average of 30% to 35% of operational costs. The problem? A large portion of this fuel is wasted through inefficient processes, undetected fraud, or fleet idleness.
In large-scale operations, even minor variations in fueling efficiency can result in millions of dollars in losses or gains per year.
This article shows how to identify these invisible losses and how automation and operational control can transform this scenario.
WHERE DO FUEL LOSSES IN MINING ORIGINATE?
Even in mines with high operational maturity, several critical issues remain:
- Fueling outside of the operational plan, undermining consumption control
- Lack of individual equipment traceability, making it difficult to combat deviations
- Fraud and theft going undetected due to the lack of real-time monitoring
- Idle fleets waiting in fueling queues, increasing non-productive consumption and reducing productivity
Each of these factors contributes to an increase in the cost per ton moved — one of the key indicators of a mine’s profitability.
THE FINANCIAL IMPACT OF FUEL LOSSES IN MINING
Let’s illustrate this with a realistic scenario:
- 20 trucks of 240 tons
- Average consumption: 400 liters of diesel per shift
- 2 shifts/day → 16,000 liters/day
- Diesel cost (2025, US average): USD 1.08/liter
- USD 17,280.00 per day in fuel costs in mining
If the mine operates with 5% fueling inefficiency, it is wasting USD 864.00 per day — or more than USD 315,000 per year.
Now imagine 10% losses. The invisible cost doubles.
HOW TO REVERSE THIS SCENARIO?
The answer lies in data and automation.
When fueling is rigorously controlled and tracked, the entire operation sees significant gains:
- Fraud and theft are identified and eliminated
- Idle time in fueling queues is reduced, increasing fleet availability
- Maintenance and fleet planning become more precise
- Carbon emissions are reduced, supporting ESG goals
THE ROLE OF AUTOMATION IN FUELING
Solutions that integrate onboard sensors, automated control, and real-time analysis enable:
- Authorizing fueling only for approved and scheduled equipment
- Recording all fueling events with full traceability
- Synchronizing fueling with the operational plan
- Generating automated reports for auditing and compliance
A PROVEN PATH
Clients who have implemented fueling automation technologies, such as Fast2Mine’s Fuel Automated, have already reported:
- Up to 10% reductions in fuel costs
- Up to 50% reduction in fueling time
- Elimination of fraud and greater data reliability
CONCLUSION
Inefficient fuel management is costly.
But with the right control and automation, it is possible to:
- Increase operational margins
- Improve fleet productivity
- Meet environmental targets
- Strengthen competitive positioning
Technology is at the service of efficiency. Operations that invest in intelligent fuel management stay ahead of the curve — leaner, more sustainable, and more profitable.
