Conveyor systems in mines, quarries and bulk processing plants are used to move large volumes of material across long distances and through complex circuits, making them an essential link in each stage of production. Continuous monitoring of these systems is critical to ensure that operations run smoothly and reliably.

This is according to conveyor systems original-equipment manufacturer (OEM) Tru-Trac. The company explains that monitoring technologies have evolved into sophisticated real-time digital systems capable of providing continuous insight into the performance of the entire conveyor line. This allows plant operators to take an integrated approach that combines condition-based and predictive strategies for proactive maintenance.

Modern monitoring systems integrate multiple data streams across the conveyor line, allowing for the measurement of belt tracking status, idler vibration, chute and skirt performance, scraper effectiveness, bearing temperatures, power draw, belt thickness and cover wear and load profiles. This enables operators to see how small deviations can trigger cascading problems – for example belt wander leads to edge damage which worsens misalignment which in turn drives spillage, cleanup costs and eventual belt replacement.

The advent of edge computing allows for monitoring to be placed closer to the source of the problem. Low power devices can now process vibration, thermal and acoustic data directly on idler frames or pulley housings enabling the detection of early signs of wear or friction. In addition, monitoring platforms increasingly translate sensor values into clear prioritised recommendations such as which idlers to replace, where to re-tension a scraper or when to inspect a chute liner.

Tru-Trac asserts that, despite the advances in monitoring technology, the fundamentals of conveyor performance remain mechanical. It advocates a holistic approach that combines mechanical excellence with digital oversight.

“An integrated approach to monitoring is no longer optional,” says Tru-Trac COO Shaun Blumberg. “You cannot look at sensors in isolation or mechanics on their own. The real value comes when you combine proven hardware with smart monitoring, so you can prevent issues before they escalate and keep the operation running at peak efficiency.”

Combining mechanical excellence, digital intelligence and structured response allows operators to reduce downtime, optimise energy consumption, extend asset life and strengthen safety, says the OEM.

“With Tru-Trac as a partner, operators are empowered not only to track their belts but to take full control of their operations, achieving consistent and predictable performance across the life of the conveyor,” Blumberg concludes.