Success Story: Operational safety in the mining industry
EPS Kostolac
OverviewChallenge
The client needed reliable and continuous communication between the spreader’s control cabin and personnel located along conveyor belts and service zones. Due to high noise, long distances, and machine complexity, traditional radio communication was insufficient. There was also a need to integrate audio communication with light and sound signaling to improve safety and response speed in emergencies.
The main challenges included high on-site noise levels, long communication distances between the cabin and conveyor workers, a limited number of operators for a large machine, and significant safety risks.
Solution
An IP-based intercom system by Commend, specifically designed for demanding industrial environments, was installed on the TEKOB3-081-BWSR coal spreader. The system enables secure and clear communication between operators in the control cabin and personnel managing conveyors and service areas. Installed devices provide reliable two-way audio communication, integration with signaling and machine control systems.
The system is fully IP-based, connected via the spreader’s internal network, enabling real-time two-way communication, signal control, and alarm integration.
Devices are designed for harsh industrial conditions with dust, noise, and vibrations.
A Commend system was chosen for its:
- Robust IP65/IP66 construction, adapted for harsh industrial conditions
- Exceptional audio clarity, thanks to digital sound processing and noise cancellation
- Modular IP architecture, allowing flexible positioning and system expansion
- Integration with signaling devices, including light and sound alarms
- High reliability and support for 24/7 uninterrupted operation
Technical data
Installed equipment includes the following components:
- 1 x GE800EU (Intercom Server)
- 5 x EE7506H (IP Industrial Intercom)
- 1 x EE380AAS (Control Desk Intercom)
- 1 x AF250H (Amplifier)
- 2 x CLS30HG70V (Horn loudspeaker)
Result
The installed Commend intercom system enabled:
- Fast and secure two-way communication between all key machine points
- Clear audio even in high-noise and vibration conditions
- Integration with machine signaling and alarm systems
- Instant cabin call from any machine location
- Increased safety and crew coordination
The project resulted in faster message transmission, improved safety, and better crew coordination. The system offers simplicity, long-term reliability, and durability in harsh conditions (IP66-rated), delivering crystal-clear sound even in noisy industrial environments.
Customer Voice
Marko Pujić
Project Manager at EPS Kostolac
For the new TEKOB3-081-BWSR spreader at EPS Kostolac, we needed a robust and reliable communication system. Commend met all requirements – from sound quality to resistance to extreme working conditions. Implementation was precise, and the system works flawlessly. We are satisfied with both the technical solution and the support during execution.
Case Study EPS Kostolac
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