ERP for Coal Washeries

Digitize Coal Processing. Optimize Yield. Control Cost & Compliance.

Coal washeries and beneficiation plants are central to coal value creation. Yet many continue to operate with fragmented systems, spreadsheets, and manual logs—leading to yield losses, inconsistent ash quality, inaccurate costing, and compliance risks.

A purpose-built ERP for Coal Washeries & Beneficiation Plants provides a single digital backbone to manage beneficiation operations, inventory, costing, assets, and compliance—enabling real-time, data-driven decision-making from ROM coal intake to washed coal output.

Consult Our ERP Experts

Key Challenges Faced by Coal Washeries Without ERP

Grade-Wise Stock Reconciliation Gaps

Manual tracking of coal by grade, size, and moisture leads to stock mismatches, reconciliation delays, and valuation errors.

Limited Visibility into Washing Performance

Lack of real-time monitoring of raw feed, WIP, washed output, and yield results in reactive firefighting and inconsistent quality.

Yield & Recovery Losses

Absence of data-driven control over cut density, circuit efficiency, and mass balance causes over-washing, under-washing, or reject losses.

High Water & Energy Consumption

Without real-time tracking of water circuits and energy usage, plants operate inefficiently, increasing operating cost per tonne.

Breakdown-Driven Maintenance

Manual inspections and reactive maintenance lead to unplanned downtime and throughput loss.

Environmental & Compliance Risks

Scattered data on slurry handling, tailings, ash levels, and emissions makes audits difficult and increases regulatory exposure.

Our Digital Mining Solutions are helping Mining Companies to Save around 18-20% Operational Cost and Enhance Productivity by 12-15%

ERP for Coal Washeries & Beneficiation Plants

Grade-Wise Stock Tracking with Batch Control

Track coal by grade, size, moisture, source, and batch across raw coal, WIP, and washed coal to ensure full visibility, traceability, and accurate valuation at every stage.

ERP Modules:

Inventory Management
Batch & Lot Tracking
Quality Management

What it Covers:
Grade-, size-, moisture-, and source-wise tracking across raw coal, WIP, and washed coal with full traceability and accurate valuation.

Yield, Recovery & Mass Balance Analytics

Analyze circuit-wise recovery, reject losses, and mass balance automatically to improve yield accountability and support informed, data-driven operational decisions.

ERP Modules:

Advanced Analytics
Production Intelligence
Reporting & BI

What it Covers:
Circuit-wise recovery analysis, reject loss monitoring, and automated mass balance to improve yield accountability and decision-making.

Integrated Weighbridge & E-Invoicing

Capture weighbridge data automatically at entry and exit points and generate compliant invoices seamlessly, eliminating manual errors and reconciliation delays.

ERP Modules:

Weighbridge Integration
Sales & Billing
Compliance & Taxation

What it Covers:
Automatic weight capture and compliant invoice generation, eliminating manual entry, billing errors, and reconciliation delays.

Live Coal Washing Process Monitoring

Monitor raw coal feed, circuit-wise WIP, washed coal output, and yield and ash parameters through real-time dashboards, enabling proactive control and consistent quality outcomes.

ERP Modules:

Production Management
Manufacturing Execution (MES)
Operations Dashboard

What it Covers:
Real-time monitoring of raw feed, circuit-wise WIP, washed output, yield %, ash %, and deviations for proactive process control.

Landed Cost & Cost-to-Produce Automation

Calculate true cost per tonne by factoring in washing losses, power, water, consumables, maintenance impact, and downtime with full cost transparency.

ERP Modules:

Costing & Finance
Cost Accounting
Management Accounting

What it Covers:
True cost per tonne calculation by integrating washing losses, power, water, consumables, maintenance impact, and downtime.

Asset Health & Predictive Maintenance

Monitor crushers, pumps, screens, cyclones, and thickeners using condition analytics to reduce unplanned downtime and extend equipment lifecycle.

ERP Modules:

Enterprise Asset Management (EAM)
Maintenance Management
IoT Integration

What it Covers:
Condition-based monitoring of crushers, pumps, screens, cyclones, and thickeners to reduce downtime and extend asset life.

Environmental & ESG Compliance Dashboards

Digitally track slurry and tailings, water consumption, energy intensity, and quality compliance to enable audit-ready reporting and reduce regulatory risk.

ERP Modules:

ESG & Compliance
Environmental Monitoring
Audit & Reporting

What it Covers:
Digital tracking of slurry, tailings, water usage, energy intensity, and quality metrics with audit-ready compliance reporting.

Explore Mining ERP

Grade-wise Stock Tracking

Batch Control

Washing Process Monitoring

WIP

Integrated Weighbridge

E-Invoicing

Reduced Cost

RPA

Efficiency & Automation

Real-time Insights

Managerial Dashboard

Budget Control

Operator Independent Truck Dispatch System (OITDS)

Complete View of Entire Mining Operations
Productivity Monitoring
Maintenance Management
Haulage Road Management & more…

Learn More

Logistics Monitoring Management
for Coal, Mineral & Metals

Vehicle Management
Multimode Transport
Route Mapping
Fleet Management & more…

Learn More

Our Testimonials

What some of Our Clients saying

“PACE360 ERP has transformed our business. We’ve seen a 25% increase in productivity and a solid Rs. 75000 approx. reduction in costs. It’s the best investment we’ve ever made.”

Somnath Chatterjee

B&A Ltd.

“With PACE360, we have complete visibility into our operations. We can now make data-driven decisions that have resulted in a 18% increase in sales.”

R.K. Poddar

Chairman, Ganges Jute Pvt. Ltd

“PACE360 has been a game-changer for our business. We’ve seen significant improvements in all areas, from efficiency to profitability. I highly recommend it to any company looking to grow.”

Sanjay Hada (MD)

Reliance Jute Mills (International) Ltd

– Real-Time Data Analysis

PACE360 Dashboard

It gathers, visualizes, and illustrates critical metrics from across the organization, offering deep insights into the performance by compellingly communicating with stakeholders a clear picture of their business in real time, thus resulting in more informed and timely business decisions.

PACE360 Dashboard is built in line with individual client’s corporate vision, operational managers’ hunger to monitor & demonstrate all small key metrics that counts, to ensure operational success, alert & alarm mechanism based on deviation in set metric to identify