Global forecasts suggest an increase in zinc production in the coming years. Along with cost, economics, and acceptance of zinc refinery products on the world market must be considered. The metals industry is facing several challenges, including a reduction in overall metal content and increased levels of impurities in the ore body and concentrate. Also, it is more important than ever to evaluate the sustainability and efficiency of the production process. The New Zinc Roaster is the result of continuous studies in the Frankfurt Research Center (historically Lurgi) and equipment development for numerous clients. Metso’s 50+ years of Fluid Bed Technology experience, coupled with a long list of international projects, has transformed the traditional roasting process. The integration of new equipment features combined with automation elements, additional sensors, and digital tools support today’s typical operation practices, to advance production targets through better control of operation and reduction of shutdown time. This article presents a short review of common practices in the industry, with a focus on how zinc concentrates high in impurities such as copper, lead, and silica are treated and how Metso is applying advanced process equipment in the fluid bed roasting process. An oven monitoring system is introduced as a method to reduce plant efficiency losses from fluid bed instabilities. The review concludes by discussing the integration of plant enhancements with modern digital tools, such as Metso’s digital solution suite for the roaster, gas cleaning, and acid plant. This approach aims to ensure increased plant safety and optimized operation, especially during upset plant conditions.