At this year’s Electra Mining Africa (EMA) event conveyor specialists Tru-Trac Rollers unveiled a suite of advanced conveyor technologies designed to enhance materials handling and optimise the performance of crushing and screening systems.

The company’s latest innovations address critical challenges in conveyor efficiency, focusing on reducing downtime and improving operational performance across the mining sector.

In conversation with Mining Weekly, Tru-Trac Rollers CEO Jonathan Rogoff emphasised the crucial role of conveyors in the materials handling process, and explains that conveyors are integral to feeding material into crushing and screening systems or removing material from these processes.

“Any problems with the conveyor system can directly impact the performance and optimisation of your crushers and screens,” he noted, highlighting that the effective management of conveyor systems is essential for maintaining overall operational efficiency.

Some of the key challenges in conveyor performance include ensuring proper belt alignment and managing heavy material from crushers.

Rogoff explained that a major issue is keeping a conveyor’s belt running true, as misalignment can lead to material spillage and potential damage to other conveyor infrastructure.

Heavy material from crushers often needs to pass through a load zone, which must be managed when material falls onto the belt, to protect the belt and keep material and dust contained using good quality skirting rubber.

To address these and other challenges, Tru-Trac Rollers has introduced the Rip Prevent+ system – a modern technology designed to detect and mitigate conveyor belt rips and anomalies.

The Rip Prevent+ system uses AI to analyse conveyor belt data in real-time, offering advanced monitoring capabilities without requiring sensors installed inside the belt, providing versatility that makes it compatible with all conveyor types, including steel cord, chevron and fabric belts.

The Rip Prevent+ system’s AI-based model monitors data 50 times a second and can alert operators through programmable logic controllers or dashboards within 0.2 seconds if a potential rip event is detected.

“By identifying increased resistance owing to stuck material or other obstructions, the Rip Prevent+ system provides pre-emptive warnings. This enables operators to address issues before they escalate, significantly reducing downtime and repair costs,” he said.

Further, the system’s Web-based interface, accessible using an ethernet network connection, features a user-friendly dashboard that displays key information. It also includes additional functions such as mass flow calculation, condition monitoring, drive or motor monitoring and electrical network analysis.

These features align with predictive maintenance strategies and enhance the overall effectiveness of conveyor systems, which are key to crushing and screening processes, as well as promoting energy efficiency, said Rogoff.

He also highlighted the system’s ease of installation and cost-effectiveness, as the Rip Prevent+ system is designed for quick and straightforward installation, typically requiring only 30 minutes to an hour for electrical connections, while commissioning can be completed within two to five hours.

In addition, Tru-Trac Rollers also offers a subscription model that reduces the initial capital investment, making it a more affordable option for many operations.

In addition to the Rip Prevent+ system, Tru-Trac Rollers also highlighted the company’s Dynamic Impact System at EMA, which features a three-way shock absorption mechanism designed to protect conveyor belts from heavy impacts.

“The Dynamic Impact System is engineered to effectively absorb shocks and transfer them away from the belt, thereby enhancing its lifespan and performance. This is particularly important for handling heavy material and reducing wear on the conveyor,” Rogoff said of the benefits.

Further, the company also introduced enhanced belt tracking technology, including new self-adjusting brackets and patented designs – innovations aimed at improving belt traction and performance, and simplifying installation.