Cold-Rolled Formed Engineering Solution Slashes Mining Scrap By 80 Pc, Cuts Costs By 10-20 Pc: Experts

Cold-rolled formed engineering solutions are driving a sustainability shift in the mining sector as the process generates minimal scrap, which can reduce waste generation by up to 80% compared to conventional methods, experts said.

As the industry focuses on productivity and sustainability, the shift toward precision-driven cold roll-formed engineering is emerging as a key enabler -- reducing waste, lowering costs, and improving long-term performance across mining operations.

"In mining, scrap is not incidental -- it is embedded cost. Traditional fabrication creates inefficiencies through cutting, welding, and overdesign. Cold roll forming addresses this at the source by minimising material loss and delivering precision-engineered profiles," said Santosh Venkatasubbaiah, Director - Sales and Marketing at Mother India Forming, a company specialising in cold roll-formed components.

Cold-rolled formed engineering solutions supports India's green steel initiatives by minimizing environmental impact through reduced material usage.

According to McKinsey & Company, maintenance accounts for 20–50% of total operating costs in mining, with structural repairs forming a notable share.

Cold-rolled formed components offer improved corrosion resistance. Unlike welded structures, where coatings are often damaged during fabrication, cold roll forming preserves surface integrity, resulting in longer service life and reduced replacement frequency.

"Frequent replacement is often a result of inconsistent fabrication... With cold roll forming, you achieve uniformity, better coating retention, and predictable performance," Venkatasubbaiah noted.

According to experts, these advantages translate into 10–20% lower replacement and maintenance costs, along with improved safety and reduced downtime.

"Mining companies are recognizing that inefficiencies in design translate into recurring costs over the lifecycle. The move toward precision-engineered systems like cold roll forming is structural, not incremental," said Pavan Kaushik, Co-founder of Gurukshetra Consultancy -- an advisory firm operating in the metals and mining sector.

"The future of mining infrastructure will be defined by efficient material use and reliable performance. Cold roll-formed engineering is emerging as a critical lever for lowering costs, improving durability, and strengthening sustainability," he added.

Globally, precision-formed metal solutions have demonstrated efficiency gains across sectors such as construction and industrial infrastructure. Mining, however, remains relatively under-optimised - making it a significant opportunity for transformation.