Next-Generation Blasting Technology
First published in the April 2025 issue of Quarry Management
Orica’s latest innovations in drilling and blasting
With a legacy spanning more than 150 years, Orica are one of the global leaders in explosives and blasting systems, providing cutting-edge solutions for the mining, quarrying, and construction industries. In the UK, Orica play a pivotal role in supporting quarry operators with advanced drilling and blasting technologies, expert training, and sustainable solutions that enhance both safety and operational efficiency.
Orica are committed to continuous innovation, developing products and services that redefine industry standards. From digital blast design and predictive modelling to environmentally responsible detonator technology, Orica are at the forefront of modern blasting solutions. The latest advancements – including Next Gen SHOTPlus, lead-free electronic detonators, and FRAGTrack – are revolutionizing the way quarries approach drilling and blasting operations, ensuring safer, more efficient, and more sustainable outcomes.
This article explores Orica’s most recent breakthroughs and how they are shaping the future of blasting in the UK quarrying industry.
Rock-on-Ground Services: A comprehensive blasting solution
Orica’s Rock-on-Ground (ROG) service is a fully integrated approach to blast management. Covering every aspect of the process – from blast design and explosives supply to pattern loading, shotfiring, and overall blast execution – ROG ensures seamless, efficient, and timely delivery of broken stock.
With a dedicated team of experts and state-of-the-art technology, Orica’s ROG service enhances productivity while maintaining the highest safety standards. This solution is particularly valuable for industries such as quarrying, surface metal mining, and surface coal operations.
By entrusting their blasting needs to Orica’s experienced crew, quarry operators can improve efficiency, optimize costs, and reduce operational risks.
Investing in industry training: Orica UK’s shotfiring courses
Recognizing the importance of skills development, Orica UK launched their Mineral Products Qualifications Council (MPQC)-accredited shotfiring courses in autumn 2024. These high-quality training programmes equip industry professionals with the technical knowledge and practical skills needed for safe and effective blasting operations.
The first course was a resounding success, with all participants passing the final examination. Building on this achievement, Orica UK will offer three additional courses in 2025 (7–11 April, 14–18 July, and 6–10 October), reinforcing their commitment to training excellence and industry safety.
By providing specialized education and hands-on experience, Orica are helping to raise safety standards and ensure best practices across the UK quarrying sector.
Revolutionizing blast design with next-gen SHOTPlus
For 35 years, SHOTPlus has been the leader in intuitive and powerful workflows for drilling and blasting professionals; to effectively improve blast designs and achieve optimal outcomes for mining, quarrying, and civil construction operations. The software enables users to design, visualize, and analyse blast sequences, leading to improved productivity, safety, and environmental performance. With an advanced 3D design environment, users can rotate and review blastholes from different perspectives, including views from the blast face and drill floor. SHOTPlus also allows for the development and automatic application of sophisticated loading rules, ensuring optimal design loading and powder factors based on actual rock conditions.
The software supports both manual and automatic blast timing and simulation, accommodating traditional systems as well as modern electronic blasting systems. Integrated diagnostic tools help identify potential issues, such as misfire risks or booster placement near inert deck interfaces. SHOTPlus is also compatible with various third-party mine planning software, allowing seamless data import of material types, hole information, and backfill data. It is fully integrated with Orica’s BlastIQ suite, streamlining data transfers and optimizing workflows.
One of the key tools within SHOTPlus is the blast exclusion tool. The blast exclusion tool will generate an exclusion zone based on user-defined model inputs and the properties of the blastholes within the SHOTPlus design plan. The blast properties considered are hole location, stemming levels, explosive charge per meter, and front row burdens. This will generate a theoretical exclusion zone based on the properties inputted by the user and provide an estimated distance that fly-rock could travel. Site-specific information should also be considered when using these estimations to define any exclusion zone.
In 2024, Orica introduced Next Gen SHOTPlus, a state-of-the-art blast design and modelling tool that is transforming drilling and blasting operations. This evolution in digital blasting technology integrates intelligent design, real-time predictive modelling, and cloud-based collaboration to maximize efficiency and performance.
At its core, Next Gen SHOTPlus leverages advanced predictive modelling to eliminate uncertainty from the drilling and blasting process. Engineers can now quantify the impact of design decisions in near real time, assessing the downstream effects on muck pile movement, fragmentation, and environmental constraints. This reduces guesswork and ensures data-driven decision-making at every stage of the blasting cycle. The next-generation tool is a game-changer for the industry, offering unprecedented levels of control, collaboration, and predictive insight.
By combining decades of expertise with cutting-edge digital advancements, Orica continue to push the boundaries of blast optimization, remaining committed to enhancing blasting efficiency, improving safety, and minimizing environmental impact across industries worldwide.
Orica’s lead-free detonators: A major step for safety and sustainability
Orica have long been committed to improving safety and reducing the environmental footprint of blasting operations. One of their most significant recent advancements is the development of fully lead-free detonators.
Following the launch of Exel Neo, the world’s first lead-free non-electric detonator, Orica have now extended this innovation to their electronic detonator range.
A major milestone was reached when Orica’s lead-free electronic detonators received CE certification, confirming compliance with stringent European safety and performance standards. Certification was granted by Germany’s Bundesanstalt für Materialforschung und -prüfung (BAM) and applies to Orica’s full range of electronic blasting systems, including eDev II Neo and i-kon III Neo.
With CE certification now in place, Orica are progressing to a comprehensive field-testing and verification programme to ensure optimal performance and reliability in all surface and underground applications, in all climate conditions. The extensive field trial programme will pave the way for the official market launch.
The fully lead-free electronic detonator delivers several safety and environmental benefits by eliminating lead from both the production process and blasting emissions. The lead-free products do not contain any Substances of Very High Concern (SVHC), according to the European Union’s Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) regulation*.
The transition to lead-free electronic detonators aligns with Orica’s ongoing commitment to reducing their environmental impact while maintaining superior performance, reliability, and safety in their operations. Eliminating lead from products can help better protect workers, communities, and the environment from harmful substances traditionally used in the mining and explosives industries in the context of the relevant EU legislation on ESG.
FRAGTrack: Precision fragmentation analysis
FRAGTrack is an advanced fragmentation-measurement tool designed to provide rapid insights into the outcome of blasting operations. Using cutting-edge vision technology, it combines hybrid AI with 2D and 3D stereoscopic imaging to deliver superior analysis in even the most challenging environments.
One of the key advantages of FRAGTrack is its ability to process fragmentation data in near real time. This allows operators to make quick, informed decisions that improve downstream processes, such as loading and hauling, crushing, and grinding.
The system features an autonomous sampling mechanism with a smart triggering system that ensures unbiased sample collection. By increasing the frequency and accuracy of fragmentation data, FRAGTrack provides quarry operators with a more reliable dataset for optimizing blast performance.
FRAGTrack is fully integrated with Microsoft Azure, offering users secure, web-based access to live and historical data. This facilitates collaboration between stakeholders, allowing them to review and analyse blast performance remotely.
The system’s localized image processing and storage ensure robust data security and integrity. FRAGTrack delivers results comparable with traditional sieve analysis, making it a trusted tool for optimizing fragmentation and maximizing operational efficiency.
Summary
Through pioneering innovations such as Next Gen SHOTPlus, lead-free electronic detonators, and FRAGTrack, Orica UK are driving the future of drilling and blasting operations. With a steadfast commitment to safety, efficiency, and environmental sustainability, the company is continuing to set new benchmarks for the quarrying industry – delivering cutting-edge solutions that optimize performance while reducing environmental impact.
As technology continues to evolve, Orica aim to remain at the forefront of innovation, ensuring that quarry operators have the tools, expertise, and support they need to achieve operational excellence.
*Orica do not use lead or lead compounds in the manufacturing of Neo detonators and take steps to seek assurances from their suppliers.
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