The elitist version of nondominated sorting genetic algorithm (NSGA II) has been adapted to optimize the industrial grinding operation of a lead-zinc ore beneficiation plant. Two objective functions have been identified in this study: (i) throughput of the grinding operation is maximized to maximize productivity and (ii) percent passing of one of the most important size fractions is maximized to ensure smooth flotation operation following the grinding circuit. Simultaneously, it is also ensured that the grinding product meets all other quality requirements, to ensure least possible disturbance in the following flotation circuit, by keeping two other size classes and percent solid of the grinding product and recirculation load of the grinding circuit within the user specified bounds (constraints). Three decision variables used in this study are the solid ore flowrate and two water flowrates at two sumps, primary and secondary, each of them present in each of the two stage classification units. Nondominating (equally competitive) optimal solutions (Pareto sets) have been found out due to conflicting requirements between the two objectives without violating any of the constraints considered for this problem. Constraints are handled using a technique based on tournament selection operator of genetic algorithm which makes the process get rid of arbitrary tuning requirement of penalty parameters appearing in the popular penalty function based approaches for handling constraints. One of the Pareto points, along with some more higher level information, can be used as set points for the previously mentioned two objectives for optimal control of the grinding circuit. Implementation of the proposed technology shows huge industrial benefits. (C) 2003 Elsevier Ltd. All rights reserved.