The leader in global spiral gravity separation installations is Mineral Technologies (MT) – which recently unveiled mtOne, which it says is a breakthrough real-time spiral automation platform. It states: “This is not just an upgrade. It’s a complete re-imagination of how spirals should operate in 2026 and beyond. Your spirals don’t need another walk-by. They need real-time intelligence with improvement at the scale of your plant.”
mtOne offers real-time visibility of spiral performance, with automated splitter control driven by smart, adaptive sensors. It also has a powerful, intuitive dashboard – shift by shift, spiral by spiral. MT argues that for decades, spirals have been treated as ‘set-and-forget’ assets. “Not anymore. mtOne is the first step towards true AI-powered spiral optimisation, turning a traditionally passive circuit into an intelligent, self-learning system. On average, up to 5% of valuable minerals are lost each day due to splitter misalignment. And without real-time data, it’s nearly impossible to know exactly when and where performance is falling short. mtOne changes that. It’s a new spiral optimisation service that puts real-time performance insights and automated control directly in your hands. With smart sensors, automated splitter adjustments, and a powerful dashboard, you can finally track how every circuit is performing – and respond immediately when conditions shift.”
The company adds: “With mtOne, sensor-driven intelligence is applied to every spiral splitter – the most critical cutting points in your plant – real-time data, and the latest AI tuning models to give you the live insights you’ve never had. With the ability to adjust every splitter at the push of a button. That’s smarter separation with measurable gains, shift after shift.”
It argues it will bring the entire plant into alignment – with smart consistency, live KPIs, and a clear view of every cut being made. “With mtOne, you’re not just watching one splitter – you’re controlling all of them, at once. Every spiral circuit tuned to the same precision cut-point. Every splitter monitored, tracked and automatically adjusted. It’s consistency across your entire plant. You’ll see what’s working and what’s falling behind, in real time.”
mtOne supports multiple operating modes to suit customer workflow:
Automatic Mode: Sensors adjust each splitter to match your target grade in real time
Set & Follow Mode: Set one spiral visually or by sensor, then sync the rest of the bank, circuit, or plant to match
Manual Mode: Set each splitter yourself. One by one, by bank, or by full circuit
Override Mode: If you need to go fully manual you can just walk up and move the splitter by hand. No restrictions, no disruption.
MT says this isn’t just automation. It’s smarter control, with flexibility built in. It is currently partnering with a select group of operators to test mtOne in the field. Behind the mtOne Splitter Automation system is a full-service team and smart software working around the clock – fine-tuning, updating, and making sure everything stays on track. “We don’t just install it and walk away. With mtOne, you get ongoing service from the most trusted spiral supplier – from remote monitoring and version updates to real-time diagnostics and auto-recovery. We provide the full suite of software and hardware support, continuously optimising your system without disruption. You might not always see us, but we’re always working to keep your spirals running at peak.”
Mineral Technologies offers a range of 20-40 spiral types, each optimised for specific mineral characteristics and separation goals. “Our spirals are designed to maximise recovery rates even with challenging ore variability, reduce tailings waste through sustainable solutions, and enhance efficiency by optimising the balance between throughput and metallurgical performance. Key features include re-pulping techniques to enhance grade and recovery; flexible configurations and adaptable designs for various processing stages; plus the use of proprietary materials as they are built for durability and consistent performance under extreme conditions.”