Case studies
Energy strategy
built on data.
Digital twin modelling & real-time monitoring — deployed across 5 substations in under 21 days, zero CAPEX.
Mixed-source network,
no unified view.
Caledonia's Blanket Mine in Zimbabwe operates a mixed-source electrical network spanning diesel gensets, grid connection, and solar PV systems, as well as distribution substations covering the whole processing plant. The installation covers mainly analogue meters of various OEMs.
VoltVision was engaged to provide a verified, accurate electrical footprint across the site — enabling site-wide Energy Transparency, Power Quality Analytics, and Automated Reporting. The ViViD Platform supports Centralised Monitoring, enabling both on-site and remote teams to track performance, support corrective actions, and improve efficiency.
ViViD Platform
live in 21 days.
- 5 substations connected across the full site — no shutdowns, no additional CAPEX
- Legacy electrical equipment of multiple OEMs seamlessly connected to the cloud — breaking down historic data silos
- Real-time, whole-site energy metrics continuously validated and historised
- Power quality analytics across all electrical sources — voltage, frequency, and power factor
- Automated Reporting with customised dashboards, KPI benchmarking, and emissions tracking
- Digital twin modelling of the electrical network to support energy strategy and CAPEX planning
- Design and control of Energy Management Strategy — with planned expansion to underground operations
Works on your existing PLCs and meters — no unplanned shutdowns.
Five substations across a mixed diesel, grid, and solar network — fully connected and streaming live data in under 21 days, zero operational shutdowns.
No upfront capital expenditure. Cloud-based deployment replaced Caledonia's in-house IT systems, with $250K+/yr in IT cost savings identified.
Static power cost savings delivered through energy management strategy and consumption optimisation across the site.
Automated Reporting replaces manual data collection and analysis — freeing key personnel for strategic work.
Reduced IT costs from migrating to a cloud-based solution, replacing expensive in-house systems.
| Benefit | What it means for Caledonia |
|---|---|
| Digitalisation | Existing analogue meters of various OEMs connected to the cloud — no replacements, no unplanned shutdowns, full historical data from day one. |
| Power Quality Analytics | Real-time monitoring of voltage, frequency, and power factor across all electrical sources — enabling early fault detection and reducing the risk of unplanned downtime across the processing plant. |
| Global Access | XCO ability to monitor electrical performance across all sites globally — a single, trusted view of energy data available to on-site and remote teams at any time. |
| Energy Management Strategy | Data-led energy management delivering up to 11% static power savings — with a structured approach to monitoring, benchmarking, and optimising consumption across the site. |
Power Quality Analytics
The site's electrical networks are continuously monitored for voltage, frequency, and power factor variations — providing real-time alerts, early warnings, and on-demand fault diagnostics. Off-site teams can remotely assess electrical performance across diesel, solar, and grid-connected sources.
Automated Reporting
Customised dashboards with 24/7 access to key metrics — including emissions tracking, energy usage, billing verification, and KPI benchmarking. Monthly executive reports and performance summaries are automatically generated, saving engineering time and standardising reporting across all departments.
Digital Twin Modelling
Using digital twin modelling of the site's electrical network and processing plant data, VoltVision helps Caledonia identify inefficiencies and shape a more efficient, data-driven energy strategy. This approach directly supports the business case for major electrical CAPEX planning and long-term energy management decisions.
Integrated Data Transparency
Time-stamped data from all meter OEMs — diesel gensets, grid connection, and solar PV — streamed into Caledonia's central platforms. This provides a full-site view of energy performance, with planned expansion to underground operations already underway.
"Implementing VoltVision's solution has been transformative for our operations team. The reporting capabilities have freed up significant time for our key personnel, allowing them to focus on more strategic initiatives rather than manual data collection and analysis. What impressed us most was how seamlessly the system integrated into our existing infrastructure — the installation process was remarkably straightforward."
See your site's data
in 30 days.
From installation to live data in under a month — on your existing infrastructure, zero CAPEX.
Download full case study PDF