Revolutionising Mineral Analysis for PSS with Automated Micro-XRF Technology

In Western Australia’s demanding resources sector, efficiency and accuracy in mineralogical analysis are paramount. For industry leaders like PSS, who specialise in spectral technology, maintaining a competitive edge means embracing innovation. This case study details how AUTONOMA, a Perth-based process automation specialist, engineered a bespoke system for automated mineralogical analysis, transforming PSS’s laboratory workflow, boosting throughput, and enabling 24/7 operation.

The Challenge: Overcoming the Limits of Manual Laboratory Processes

PSS faced operational bottlenecks common in high-volume analytical labs. Their existing manual process for preparing and analysing mineralogical samples was hindered by tasks that were dull, difficult, and time-consuming, creating significant inefficiencies.

• Dull & Repetitive Tasks: Highly skilled technicians were spending valuable time on the monotonous, repetitive work of manually loading and unloading samples into a Micro-XRF (µXRF) instrument. This not only consumed skilled labour but also increased the risk of human error in sample placement.
• Difficult & Laborious Work: The physical demands of constant sample handling contributed to operator fatigue, impacting both job satisfaction and sustained concentration, which is critical for accurate analytical work.
• Operational Inefficiency: The manual workflow inherently limited sample throughput. The entire process was constrained by standard work hours and the physical capacity of the technicians, creating a ceiling on the lab’s potential output and delaying the delivery of crucial analytical insights to their clients.
• Scalability Constraints: As demand for their services grew, PSS recognised that their manual process was not scalable. Simply hiring more staff would not solve the core issue and would lead to diminishing returns.

PSS needed a forward-thinking solution to break through these constraints, one that could elevate their operational capacity and future-proof their business for growth.

The Solution: A Bespoke Robotic System for Automated Mineralogical Analysis

AUTONOMA collaborated closely with the PSS team to co-develop a fully customized, intelligent automation system. Our Perth-based engineers applied our full project lifecycle approach—from initial consultation and design to implementation and support—to create a solution that precisely met PSS’s goals.

The core objective was to design a robust, “lights-out” system capable of continuous, reliable operation even in a demanding laboratory environment. The key deliverables were:

• Increase Throughput: Automate the time-consuming, repetitive procedures to dramatically accelerate the analysis cycle without compromising the high accuracy PSS is known for.
• Enable 24/7 Operation: Deploy a safe, autonomous system that could run overnight and on weekends with minimal human intervention, effectively tripling operational hours.
• Enhance Human-Robot Collaboration: Free highly qualified technicians from low-value manual tasks, allowing them to focus on complex data interpretation, quality control, and client engagement.
• Build a Scalable Platform: Engineer a modular and scalable solution that could easily handle growing sample volumes and support PSS’s long-term business expansion plans.

System Integration: The Fusion of Robotics and Advanced Analytics

Our expertise lies in integrating world-class hardware with intelligent custom software. For PSS, we engineered an end-to-end system built around two core components, creating a seamless workflow for their automated mineralogical analysis.

• KUKA LBR iiwa Collaborative Robot: We selected this advanced “cobot” for its exceptional precision, contact sensitivity, and safety features. It allows for safe human-robot collaboration within a shared workspace. The KUKA arm was programmed to perform the delicate and precise task of picking, placing, and removing samples from the analyser with perfect repeatability.
• Bruker M4 TORNADO Micro-XRF: The system was designed around PSS’s existing leading instrument for detailed micro x-ray fluorescence (µXRF) analysis. Our solution ensured perfect interaction with the analyser’s stage, maximising the instrument’s uptime and analytical potential.
• Custom Sample Handling: AUTONOMA designed and fabricated bespoke sample trays and handling mechanics. This critical engineering step ensured that mineralogical samples were consistently positioned and delivered for accurate µXRF readings every single time, a cornerstone of reliable data.
• Intelligent Control Software: The entire process is orchestrated by a central control system developed by AUTONOMA. This intuitive interface allows technicians to easily load sample batches, initiate runs, and monitor progress, while the system handles the complex robotic movements and instrument handshaking autonomously.

The Results: A Paradigm Shift in Laboratory Efficiency and Capacity

By implementing the AUTONOMA-designed automated Micro-XRF system, PSS achieved a significant and measurable transformation in their operations, delivering a clear return on investment.

• Massive Increase in Capacity: The lab can now process a significantly higher volume of samples, meeting growing client demand with ease and confidence. The system effectively multiplies the output of a single µXRF instrument.
• Continuous 24/7 Operation: The autonomous system operates around the clock. Technicians can load a full batch of samples at the end of the day and return the next morning to a completed analysis run, ready for interpretation.
• Dramatic Efficiency Gains: The analysis time per sample was drastically reduced due to the elimination of manual changeover delays. The robotic system works tirelessly and efficiently without breaks or fatigue.
• Improved Work Environment: Technicians are no longer tied to repetitive, laborious tasks. They are now empowered to focus on higher-value work, including data analysis and process improvement, boosting both productivity and job satisfaction. Our bespoke automation services are designed to achieve this kind of operational uplift.

This project is a powerful example of how targeted industrial automation can revolutionize laboratory workflows. Through a tailored blend of advanced robotics, intelligent software, and expert process engineering, AUTONOMA empowered PSS to modernise their mineralogical analysis and unlock new levels of efficiency, safety, and scalability. Partnering with AUTONOMA enables businesses across Western Australia to future-proof their operations and thrive in a competitive, data-driven world.

Ready to Build a Smarter, More Efficient Operation?

Stop forcing your business to fit inadequate software. Invest in a bespoke solution designed to unlock your full operational potential and deliver a clear return on investment. Contact the AUTONOMA team today for a no-obligation consultation to discuss your software development needs.

Call us on +61 8 6149 9801 or complete our online inquiry form to bring your vision to life.