Projects

Innovation in Cathode Stripping Machine Manufacturing: A Custom Robotic System for a Comprehensive Automation Project

Mario Portilla, Automation Manager at EPCM South America

Client

Our client, one of the world’s leading mining companies, operates across multiple continents and is constantly seeking to optimize its industrial processes. At its African operation, the company identified the need for a custom manufacturing solution for cathode stripping — a critical step in the production of high-purity copper.

Challenge

The client required a robust and reliable stripping machine, engineered for continuous, safe, and efficient operation in demanding industrial environments. The previous equipment — generic in design — presented limitations such as high levels of manual intervention, maintenance difficulties, and inconsistent cathode extraction.

The challenge was clear: to design and manufacture a specialized robotic system with optimized mechanical and electrical integration that meets high standards of quality, ergonomics, and workplace safety.

Solution

EPCM – COBRA approached the challenge with a fully integrated strategy. The solution included:

• Complete mechanical design with validated 3D and 2D drawings
• Dedicated hydraulic system to ensure consistent operational force
• Industrial-grade electrical panel with PLC and HMI, fully mounted and wired to international standards
• Physical safety interlocks (gated access, emergency stop sensors)
• Factory Acceptance Testing (FAT), simulating real operating conditions using dummy cathodes
• A comprehensive documentation package: manuals, spare parts lists, and electrical and pneumatic diagrams

Additionally, a functional risk assessment was conducted, and Reliability-Centered Maintenance (RCM) principles were applied to ensure optimal performance throughout the equipment’s lifecycle.

For this project, EPCM proposed a design that significantly decreased the capital costs compared to the original concept — highlighting our ability to think differently and deliver smarter, value-driven solutions for our clients.

Outcome (In Progress)

The equipment is currently in the final manufacturing stage, with testing scheduled at EPCM – COBRA’s facility. The robotic system is designed to process up to 120 cathodes per hour, achieving an optimized cycle time and reducing downtime by 40% compared to the previous solution.

Its modular design will allow for future system expansions or replication at other client facilities in the region. Moreover, the system stands out for its adaptability to brownfield projects, requiring minimal modifications to existing plant layouts. This implementation will not only enhance operational efficiency but also pave the way for Industry 4.0 practices through remote monitoring and predictive maintenance.

Trusted Expertise that Delivers Results

With over 45 years of global experience, EPCM offers complete lifecycle solutions — from conceptual engineering to post-sale support — that turn complex industrial processes into stable, safe, and productive operations.

Contact us to discover how our expertise can help you achieve your operational goals.