How Orica supported Northern Star Resources to deliver scalable, remote blast initiation

Fimiston Underground, part of Northern Star’s Kalgoorlie operations, required a scalable solution to manage complex, multi‑area blasting. Orica implemented the Omni Remote Blasting System (ORBS™), enabling secure, centralised blast initiation from surface. The solution reduced personnel exposure, improved coordination across mining zones, and delivered consistent, reliable blast outcomes, supporting long‑term underground growth and operational efficiency.

Site profile

Fimiston Underground mines high‑grade extensions of the Fimiston gold system beneath the Super Pit. The operation uses long hole open stoping with paste fill and integrates with Northern Star’s Kalgoorlie processing infrastructure. 

The project began in June 2023 and is evolving into a long‑life underground operation, supporting broader regional growth.

The challenge: managing centralised firing across multiple underground zones

Fimiston Underground expanded rapidly into a complex, multi‑mine environment including United Consols, Union Jack, Golden Pike Stockworks, and Croesus. Each area operated with independent services and ventilation systems. 

This created challenges including:

• coordinating blasting across geographically separated zones
• maintaining consistent blast timing and outcomes
• ensuring safe firing within a shared underground network
• increasing operational complexity as the mine scaled

A centralised, reliable and safe blasting approach was required to support continued growth.

The solution: ORBS™ omni remote blasting system

Orica deployed ORBS™, a network‑enabled blasting system that allows secure, remote initiation from a central location using the mine’s underground LAN.

Key capabilities

• centralised remote blast initiation across all mining areas
• secure, browser‑based access with user authentication
• real‑time blast monitoring, reporting and data capture
• scalable architecture supporting up to 30 Blaster 3000 units

This solution enabled synchronised blasting across multiple zones while reducing reliance on traditional firing lines and decreasing exposure of personnel underground.

The result: safer, more efficient and coordinated blasting

Proven performance during commissioning

• 14 successful live firings (10 development, 4 production)
• all blasts initiated remotely from surface
• zero reported issues during commissioning
• confirmed system reliability and network stability

Operational benefits

• reduced blast setup time and infrastructure requirements
• improved end‑of‑shift blasting efficiency
• increased utilisation of production hours
• reduced re‑entry delays
• consistent blast execution across multiple zones

Safety and governance improvements

• reduced personnel exposure in active underground areas
• improved traceability through centralised access and reporting
• enhanced oversight of development and production blasting

Long‑term impact

Since commissioning in July 2025, ORBS™ has been adopted as the primary system for production blasting, with expansion into development blasting from June 2026. 

The system supports:

• sustained productivity improvements
• reduced operating cost per blast
• improved blast reliability
• scalable growth for future underground expansion

Customer testimonial

Implementing the ORBS™ blasting system for our underground production blasts at KCGM has been a significant step forward for our underground operations.
We’ve seen noticeable improvements in operational efficiency and blast consistency. Having a centralised system has streamlined our firing processes and improved safety by ensuring the underground is clear before initiation.

Miguel Bachiller
Mining Manager – Underground
Northern Star Resources, KCGM

Why ORBS™?

ORBS™ delivers a step change in underground blasting through:

• centralised control across complex operations
• improved safety through remote initiation
• data‑driven decision making
• scalable infrastructure for growing mines

Acknowledgements

Orica are grateful for the collaboration with Northern Star Resources at Fimiston Underground, giving us the opportunity to jointly find improvements for your operation through this ORBS™ implementation, while complying with safety standards, maintaining positive interaction with communities and preserving the environment.