“So it’s crushing up the massive rocks into the small, tiny rocks and then processing that, our technical term is a flow sheet.”

Sam Warmerdam, Sustainability Manager at FLS.

In this episode of the Next stop: Green business podcast series, we visit FLS at their headquarters in Copenhagen. As a global leader in mineral processing technology, FLS provides the solutions that help turn raw rocks into the critical minerals needed for everything from wind turbines to electric vehicles.

With demand for metals like copper, lithium and aluminium rising rapidly in the green transition, the mining industry faces mounting pressure to reduce its environmental impact. That’s where FLS comes in. From improving energy efficiency to minimising water use and lowering the total cost of ownership for mining customers, FLS is helping reshape one of the world’s most resource-intensive industries.

We speak with FLS representatives about what it means to balance global demand with local impact, and how sustainability — when done right — can also be a lever for competitiveness.

Tag along for the journey of the rocks.

Rethinking mining from the ground up

FLS doesn’t extract minerals itself. Instead, they develop full flowsheet solutions that help mining companies grind, crush and concentrate ore more efficiently. And with mineral processing alone accounting for around 3% of global electricity use, improving this part of the value chain can make a real difference.

“If our solution provides, on average, 30% efficiency,” says Amrani, “it’s a back-of-the-envelope calculation, but it’s about 1% of global electricity.”

In addition to energy, mineral processing consumes significant amounts of water. FLS solutions are designed to recycle up to 95% of water on-site — an increasingly important feature in a resource-constrained world.

But for FLS, the challenge isn’t just technical. It’s also social. The company recognises that local communities are central to the mining industry’s social license to operate, and that environmental performance is key to building trust.

“Mines will have a hard time if they’re not getting the approval of the local communities,” says Amrani. “If they can demonstrate that they’re having the least environmental impact, it will be part of the answer.”

That’s why FLS integrates energy and water efficiency into the entire mineral processing stage — from site-specific equipment combinations to technologies that reduce downtime and extend product lifespan.

“What that means is the products last longer, so you don’t need to replace them as much,” explains Warmerdam. “They don’t break down as much, so you have less downtime… and energy efficiency means there’s less operating cost.”

Ultimately, sustainability is not just about responsibility — it’s also a source of competitiveness.

“If you don’t innovate and improve, someone else will and will be able to push you out of your market space,” says Warmerdam.

Still, the path forward is complex. As Amrani puts it:

“It’s not a walk in the park. If you want to make a difference, there are so many opportunities. And that’s what is attracting us to this sector — and hopefully more people in the future.”

About the podcast: Next stop: Green business

Next stop: Green business is part of State of Green’s podcast universe and offers short, accessible episodes of no more than 15 minutes. Each episode focuses on one company’s green transition journey, recorded on-site to capture both atmosphere and authentic voices.

The podcast blends interviews, real-time conversations and on-site impressions, all shaped around a recurring set of questions that invite honest reflection and personal insights. Besides FLS, the podcast series includes episodes with companies such as Danfoss, Grundfos, ROCKWOOL, PensionDanmark, Hempel, NKT, Schneider Electric and VELUX. New episodes will drop throughout the remainder of 2025.

The miniseries is available on Spotify, Apple Podcast and stateofgreen.com.