Projects
Anode Preparation Automation in Central Europe: EPCM’s Robotic APM Solution
By Bill Torrens, General Manager at EPCM Automation & Daniel Chaplin, General Manager at EPCM Engineering
Client
One of the world’s leading copper and silver producers, with strategic operations in Central Europe, is undertaking a major modernization project at its refining facility. In collaboration with a local engineering firm, the company aimed to improve operational efficiency, consistency, and automation in anode preparation — a key stage in the copper refining process.
Challenge
The goal of the project was to modernize and automate copper anode preparation while ensuring high levels of precision, reliability, and efficiency. Conventional solutions available on the market posed significant limitations: large footprints, complex mechanical configurations, and limited flexibility to adapt to the existing plant layout.
In addition, manual or semi-automated processes caused variations in anode thickness, lug alignment, and verticality — all of which negatively impacted final product quality and tankhouse performance.
The client sought a solution that could overcome these limitations and integrate seamlessly into the existing layout, minimizing human intervention and maximizing precision.
Solution
EPCM’s Automation Division proposed an advanced Robotic Anode Preparation Machine (APM) — a fully automated, compact, and high-performance cell designed to process approximately 400 anodes per hour at 90% OEE. The project includes the delivery of two identical APM cells, each equipped with:
- Two multi-axis robots providing continuous anode control
- A linear transfer conveyor replacing traditional walking beam systems, enabling faster indexing between stations
- A compact mechanical layout integrating pressing and milling stations while minimizing footprint
Each APM cell follows a complete operational sequence, including:
- Anode bundle splitting and individual weighing
- Robotic loading and unloading
- Multi-point body and lug pressing with integrated thickness sensors
- Face and lug milling using electric drives
- AI-based inspection system to validate milling quality and verify dimensional tolerances
- Infeed and outfeed reject racks to handle out-of-specification anodes
The design also includes crane- and forklift-compatible interfaces to support efficient material and reject handling.
Beyond equipment, EPCM’s system offers scalability and adaptability — the robotic cell can be easily reconfigured to suit spatial constraints and future process modifications.
Additionally, the APM is designed with operator safety and maintenance efficiency in mind. The reduction of manual handling minimizes exposure to mechanical risks, while the use of electric drives and modular components simplifies servicing and reduces downtime. An intuitive control interface and built-in diagnostics further contribute to safer, more reliable, and easier day-to-day operation.
Outcome (In Progress)
The APM solution is currently in the advanced design and fabrication phase, with deliveries scheduled in two stages. Installation is planned for Q3 of 2025. Once operational, the cells are expected to significantly reduce operational variability, improve anode preparation quality, lower maintenance costs through advanced automation, and enhance overall safety in daily operations.
This initiative represents a clear step toward the adoption of Industry 4.0 practices in base metal refining. With AI-driven inspection, real-time reject management, and consistent mechanical preparation, the APM system is set to redefine how anode preparation is carried out across the industry.
Looking Ahead
At EPCM, we bring over 45 years of global experience in engineering and automation to deliver solutions that enhance reliability, safety, and long-term performance. Our Anode Preparation Machine is a clear example of how we integrate robotics and intelligence into critical operations in the mining and metallurgical industries.
For more information on this groundbreaking project and others, send us an email at info@epcm.com or visit our website: www.epcm.com
