Dazhong Mining deploys a full-staff production and maintenance system based on Xerafy industrial RFID tags
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Dazhong Mining Deploys Full-Staff Production and Maintenance System Using Industrial RFID Tags
Dazhong Mining, a major iron ore producer with operations in Inner Mongolia and Anhui provinces, has successfully deployed an industrial-grade asset tracking system based on Xerafy Cargo Trak II RFID tags and mobile handheld readers. The system supports the company’s Total Productive Maintenance (TPM) strategy by significantly improving equipment availability tracking, maintenance record accuracy, and operational efficiency. This case study illustrates how industrial RFID technology is transforming traditional mining operations through reliable, automated identification.
Operational Challenges in Large-Scale Mining
Dazhong Mining operates across a 20-square-kilometer mining area in Inner Mongolia—roughly one-third the size of Manhattan. The site includes four underground mines with an annual output of 1.8 million tons of iron ore. Over 900 employees work in shifts, 24 hours a day, at depths exceeding 900 meters below the surface.
The extraction and processing of iron ore involves multiple stages: crushing, grinding, magnetic separation, flotation, and gravity separation. Each stage relies on heavy mechanical equipment distributed across a vast, harsh environment. The company also produces iron pellets for blast furnace ironmaking and iron ore concentrate powder for steel smelting.
Before deploying RFID, Dazhong Mining conducted all asset tracking manually. Annual full-asset inventories required approximately two months to complete. Inspection teams carried thick paper checklists, walking from ground level to underground tunnels, recording each asset by hand. Data was later entered into the company’s system manually—a process prone to human error, missing records, and significant time loss.
The core objective was to support a Total Productive Maintenance (TPM) system, specifically the TnPM (Total Normalized Productive Maintenance) methodology widely adopted in China. TPM aims to maximize equipment effectiveness through proactive and preventive maintenance involving all employees. Without accurate, real-time asset data, achieving TPM goals was virtually impossible.
Why RFID Was the Right Solution for Mining Asset Management
Dazhong Mining evaluated several technologies before selecting RFID. Barcode systems were rejected because of reading distance limitations and susceptibility to dirt, moisture, and abrasion in underground conditions. Manual methods were too slow and error-prone for a site spanning 20 square kilometers with thousands of critical assets.
RFID offered three key advantages for this use case:
- Non-line-of-sight reading: Tags can be read even when covered by dust, grease, or equipment components.
- Batch reading capability: Multiple assets can be identified simultaneously from a distance, drastically reducing inspection time.
- Durability: Industrial-grade tags withstand extreme temperatures, vibration, moisture, and mechanical shock found in mining environments.
The company specifically needed an RFID system that could interface with its Computerized Maintenance Management System (CMMS) to automate data collection and trigger maintenance workflows.
Product Selection: Xerafy Cargo Trak II Industrial RFID Tags
After evaluating multiple options, Dazhong Mining selected Xerafy’s Cargo Trak II tag, part of the Outdoor Trak series. This UHF RFID tag is engineered specifically for field operations, including underground mining, construction, and heavy industrial environments.
Technical Specifications of Cargo Trak II
- Unique identification number per tag for individual asset tracking
- IP68 waterproof rating, protecting against dust and continuous immersion in water
- Read range up to 12 meters on metal surfaces, 6 meters on non-metal surfaces
- Compatible with both metal and non-metal equipment, providing a universal tagging solution
- Rivet holes for secure permanent installation, with optional adhesive or cable tie mounting
- Robust housing resistant to vibration, impact, and extreme temperatures
The tag’s ability to perform on both metal and non-metal surfaces was critical. Mining equipment varies widely—from steel machinery frames to rubber conveyor belts and composite components. Using a single tag type across all assets simplified procurement, training, and deployment.
Comparison with Alternative Tags
For operations requiring different form factors, manufacturers offer various RFID tags optimized for specific surfaces, read ranges, and environmental conditions. The Cargo Trak II was selected because it met the extreme durability requirements of underground mining without compromising read performance. Standard consumer-grade tags would fail within weeks under similar conditions due to water ingress, adhesive degradation, or antenna damage.
Deployment Process and Integration
Xerafy worked closely with Dazhong Mining’s engineering team to deploy the RFID system across two mine sites: one in Inner Mongolia and one in Anhui province. The deployment followed a structured approach:
Phase 1: Asset Tagging
Each critical asset was fitted with a Cargo Trak II tag. Tags were attached using rivets for permanent assets like crushers, mills, and conveyors. For equipment that required periodic replacement or maintenance, adhesive and cable tie options were used. Over 270 assets were tagged in the initial rollout, including extraction equipment, processing machinery, ventilation systems, and safety-related devices.
Phase 2: Reader Deployment
The company deployed mobile PDAs with integrated RFID functionality. These handheld devices allowed inspection teams to read tags from distances up to 12 meters, even in low-light underground conditions. The PDA was equipped with a custom asset inventory application that automatically recorded tag IDs, timestamps, and GPS location data.
For operations requiring fixed reading points, such as entry/exit portals or maintenance bays, RFID readers can be installed permanently to capture asset movements automatically. Dazhong Mining opted for a mobile-first approach due to the distributed nature of its assets and the need for flexible inspection routines.
Phase 3: System Integration
The RFID system was integrated with Dazhong Mining’s existing CMMS. Tag reads were automatically fed into maintenance schedules, triggering work orders when equipment reached predefined service intervals. The system also supported the TnPM methodology by providing real-time visibility into equipment status, enabling proactive maintenance before failures occurred.
As a leading RFID reader manufacturer, Xerafy ensured full compatibility between the tags and the handheld readers, using standard UHF RFID protocols (EPC Gen2 / ISO 18000-6C) to guarantee interoperability across the supply chain.
Measurable Results: 50% Reduction in Inspection Time
The results of the deployment were immediate and quantifiable. Mr. Tian Gong, responsible for on-site asset tracking and equipment management at Dazhong Mining, reported:
“In the past, it usually took about 2 weeks to find, identify, and record 272 on-site assets. After using the RFID system, it can be completed in less than 1 week, saving 50% of the time while ensuring the completeness and accuracy of the data.”
Key Performance Improvements
- Inventory time reduced by 50%: Annual full-asset inventory dropped from 2 months to approximately 1 month.
- Data accuracy improved: Manual transcription errors were eliminated, ensuring maintenance records were complete and reliable.
- Safety compliance enhanced: Critical safety-related equipment could be inspected daily with verifiable electronic records.
- Employee productivity increased: Workers spent less time on paperwork and more time on actual maintenance tasks.
- TPM/KPI tracking enabled: Equipment availability, mean time between failures, and maintenance compliance could be measured accurately.
Broader Applications: From Mining Equipment to Fixed Assets
Following the successful deployment on production equipment, Dazhong Mining is now expanding the RFID solution to cover fixed assets and office equipment. This includes computers, furniture, vehicles, and other non-production items that require tracking for financial auditing and lifecycle management.
In retail and logistics environments, similar RFID solutions are used for inventory management and loss prevention. For example, RFID tags on clothes enable garment retailers to track inventory in real-time, reducing out-of-stocks and improving customer satisfaction. While the application differs, the underlying technology—UHF RFID—provides the same benefits of speed, accuracy, and automation.
Deployment Considerations for Industrial RFID
Based on this case study, organizations considering industrial RFID deployments should evaluate the following factors:
Environmental Durability
Mining, oil and gas, and heavy manufacturing environments expose tags to extreme conditions. Tags must be rated for:
- Temperature extremes (from -40°C to +85°C or wider)
- Water, dust, and chemical exposure (minimum IP67 or IP68)
- Mechanical shock and vibration
- Abrasion from rocks, tools, or moving parts
Read Range Requirements
In underground mines, long read ranges are essential because assets may be located in hard-to-reach areas. The Cargo Trak II’s 12-meter range on metal allowed inspectors to read tags from a safe distance, reducing the need to climb onto machinery or enter confined spaces.
Tag Attachment Methods
Permanent installation using rivets or bolts ensures tags stay attached even under vibration. Adhesive-only mounting may be sufficient for indoor fixed assets but is not recommended for heavy industrial equipment. Cable ties offer a compromise for temporary or rotating assets.
Reader Selection
Choosing the right RFID reader depends on use case requirements. Mobile readers, like those used by Dazhong Mining, are ideal for inspection rounds and field asset tracking. Fixed readers are better suited for choke points such as doorways, conveyor belts, or maintenance bays where automatic detection is needed.
Industry Insights: RFID Adoption in Mining and Heavy Industry
The global mining industry is increasingly adopting IoT and RFID technologies to improve safety, reduce downtime, and meet sustainability targets. According to industry reports, RFID-enabled asset tracking can reduce maintenance costs by 15-30% and extend equipment lifespan by enabling condition-based maintenance rather than time-based maintenance.
The success at Dazhong Mining demonstrates that RFID is not just for retail or logistics—it is a proven technology for the world’s harshest environments. With tags like the Cargo Trak II offering industrial-grade durability, mining companies can achieve the same levels of automation and accuracy that retailers have enjoyed for years.
One key trend is the convergence of RFID with other Industrial Internet of Things (IIoT) sensors. For example, combining RFID tags with temperature, vibration, or humidity sensors allows predictive maintenance by monitoring equipment health continuously. While Dazhong Mining’s current system focuses on identification and location tracking, the infrastructure is ready to support future sensor integration.
Another trend is the use of handheld devices that combine RFID, barcode scanning, and GPS in a single ruggedized unit. This allows inspection teams to capture all relevant data in one pass, further improving efficiency. The PDAs used by Dazhong Mining already support this multifunction approach.
Frequently Asked Questions (FAQ)
1. What type of RFID tag works best in mining environments?
Industrial UHF RFID tags with IP68 or higher waterproof and dustproof ratings are recommended. Tags designed for metal surfaces, such as the Xerafy Cargo Trak II, provide reliable performance on mining equipment. Tags with rivet holes for permanent attachment are preferred over adhesive-only solutions in high-vibration environments.
2. How does RFID improve total productive maintenance (TPM)?
RFID provides accurate, real-time data on equipment location, usage, and maintenance history. This data enables TPM by ensuring that preventive maintenance is performed on schedule, reducing unplanned downtime, and involving all employees in equipment care. The automated data collection eliminates manual errors and frees workers for value-added tasks.
3. Can RFID tags be read underground or in low-light conditions?
Yes. UHF RFID does not require line-of-sight or visible light to operate. The tags communicate using radio waves, which penetrate dust, grease, and darkness. Dazhong Mining confirmed that their PDAs could read tags reliably at depths of 900 meters underground with no ambient light.
4. What is the typical read range for industrial RFID tags on metal equipment?
High-performance tags like the Xerafy Cargo Trak II achieve read ranges up to 12 meters on metal surfaces. Standard tags may offer only 2-5 meters on metal. Read range also depends on the reader power output, antenna configuration, and environmental interference.
5. How do you attach RFID tags to mining equipment permanently?
For permanent installation, tags with rivet holes should be mechanically fastened using stainless steel rivets or bolts. This ensures the tag remains attached under vibration, shock, and thermal expansion. For equipment that is replaced regularly, adhesive or cable tie mounting may be acceptable.
6. Can the same RFID tag be used on metal and non-metal surfaces?
Some industrial UHF RFID tags, including the Cargo Trak II, are designed to work on both metal and non-metal surfaces. This universal capability simplifies deployment because a single tag type can be used across different equipment categories. Always verify the tag’s datasheet for performance specifications on each surface type.
7. How does RFID integrate with existing CMMS or ERP systems?
RFID readers capture tag IDs and timestamp data, which is transmitted to middleware software. The middleware formats the data and sends it to the CMMS or ERP via standard APIs or database connectors. Dazhong Mining’s system automatically triggered maintenance work orders based on tag reads, ensuring seamless integration with their existing maintenance platform.
8. What is the difference between passive and active RFID for industrial asset tracking?
Passive UHF RFID tags, like the Cargo Trak II, have no internal battery. They are powered by the reader’s radio signal, making them low-cost, maintenance-free, and suitable for long-term deployment. Active RFID tags have internal batteries and offer longer read ranges but are more expensive and require battery replacement. For most asset tracking applications in mining, passive UHF provides the best balance of cost, performance, and durability.
Conclusion
The deployment at Dazhong Mining is a compelling example of how industrial RFID tags can transform asset management in heavy industries. By selecting the right tag for the environment, integrating with existing CMMS systems, and training staff on mobile reader operation, the company achieved a 50% reduction in inspection time, improved data accuracy, and laid the foundation for a comprehensive TPM program.
As the mining and heavy industrial sectors continue to digitize, RFID technology will play an increasingly central role in safety, efficiency, and sustainability. The lessons from Dazhong Mining’s success are applicable to any organization managing large numbers of assets in challenging environments.
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