Predictive Maintenance for Conveyors
Prevent costly conveyor failures with AI-powered predictive maintenance specifically designed for conveyor systems. Monitor belt tracking, bearing health, motor performance, and alignment issues to reduce downtime by 70% and extend belt life by 50%.
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Common Conveyor Failures We Detect
Our AI-powered system identifies and predicts the most costly conveyor failures before they cause unplanned downtime.
Belt Tracking Issues
Misaligned belts cause edge damage, material spillage, and premature wear.
- Belt edge fraying and cuts
- Material spillage and cleanup costs
- Premature belt replacement
Bearing & Roller Failures
Worn bearings in rollers and drive components cause vibration and noise.
- Increased friction and energy costs
- Seizure and belt damage
- Secondary equipment damage
Motor & Drive Problems
Electrical and mechanical issues in drive motors and gear reducers.
- Motor overloading and overheating
- Gear reducer wear and leaks
- Belt slip and speed variations
Material Buildup
Accumulation of material causing blockages and carryback issues.
- Chute and transfer point blockages
- Belt cleaning system failures
- Carryback and cleanup issues
Belt Splice Failures
Mechanical and vulcanized splice deterioration over time.
- Splice separation and belt breaks
- Uneven thickness and tracking
- Emergency shutdown events
Structural Vibration
Frame and support structure vibrations affecting performance.
- Loose bolts and connections
- Foundation settlement issues
- Resonance and fatigue damage
Advanced Conveyor Monitoring Technology
Our comprehensive monitoring system uses multiple sensor types and AI analytics to provide complete visibility into conveyor health and performance.
Vibration Analysis
Continuous vibration monitoring on motors, rollers, and belt systems to detect bearing wear, imbalance, and alignment issues.
Computer Vision
AI-powered visual inspection monitors belt tracking, material flow, and structural conditions continuously.
Load & Current Analysis
Motor current signature analysis detects mechanical loading changes, belt slip, and drive system problems.
Sensor Technologies
Monitoring Capabilities
- Real-time belt tracking and alignment monitoring
- Predictive bearing failure detection 4-8 weeks early
- Material flow rate and blockage detection
- Energy efficiency optimization alerts
Industry Applications
Conveyor predictive maintenance delivers critical value across industries where material handling is essential to operations.
Mining Operations
Critical for continuous ore transport with harsh operating conditions.
Manufacturing
Production line conveyors where downtime stops entire operations.
Logistics & Warehousing
Package sorting and distribution systems requiring high reliability.
Food Processing
Hygienic material handling with contamination prevention.
Complete Conveyor System Integration
Our solution integrates seamlessly with existing conveyor control systems and provides comprehensive monitoring coverage.
Edge Computing
Local processing for real-time decisions and reduced latency in critical applications.
SCADA Integration
Direct integration with existing PLC and SCADA systems for unified operations.
Mobile Monitoring
Real-time alerts and remote monitoring through mobile applications.
Industrial Security
Cybersecurity protocols designed for industrial OT environments.
Implementation Process
Typical Installation
Complete conveyor monitoring system deployed in 2-3 days with minimal operational disruption.
- • 10-20 wireless sensors per conveyor system
- • Cloud connectivity through industrial gateway
- • Real-time monitoring within 24 hours
Conveyor Maintenance ROI Calculator
Calculate your potential savings from predictive maintenance on conveyor systems.
Prevent unexpected failures with early warning detection
Proper tracking and tension management extends belt lifespan
Optimized operation reduces power consumption and costs
Fast payback through reduced maintenance and downtime costs
Cost Savings Example: Mining Conveyor System
Before Predictive Maintenance
- Annual downtime cost:$4,800,000
- Emergency repairs:$1,200,000
- Belt replacements:$800,000
- Total Annual Cost:$6,800,000
After Predictive Maintenance
- Annual downtime cost:$1,440,000
- Planned maintenance:$600,000
- Belt replacements:$400,000
- Total Annual Cost:$2,440,000
Case Study: Coal Mine Conveyor System
How predictive maintenance transformed operations at a major coal mining facility.
The Challenge
- 5.2km overland conveyor experiencing frequent belt tracking issues
- Monthly unplanned downtime averaging 48 hours
- Belt replacement every 18 months due to edge damage
- $2.3M annual cost from downtime and maintenance
The Solution
- 85 wireless sensors across drive stations and critical points
- AI-powered belt tracking and bearing health monitoring
- Real-time alerts to control room and mobile devices
- Integration with existing SCADA and maintenance systems
Results After 12 Months
Technical Specifications
Comprehensive monitoring coverage designed specifically for conveyor system requirements.
Sensor Specifications
- Vibration Range: 0.1-6,000 Hz
- Temperature Range: -20°C to +80°C
- Wireless Range: Up to 40m line-of-sight
- Battery Life: 5+ years typical operation
- IP Rating: IP69 weatherproof protection
- Sampling Rate: Up to 25.6 kHz
Monitoring Points
- Drive Motors: Vibration, current, temperature
- Head/Tail Pulleys: Vibration, temperature
- Gear Reducers: Vibration, oil temperature
- Roller Stations: Temperature, rotation status
- Belt Surface: Temperature, tracking position
- Take-up Systems: Tension, position monitoring
Alert Capabilities
- Bearing Warnings: 4-8 weeks advance notice
- Load Monitoring: 10% variance detection
- Speed Variations: 1% slip detection
- Temperature Alarms: 5°C rise above baseline
- Emergency Stops: Critical failure prevention
Transform Your Conveyor Maintenance Today
Join the mining and industrial companies already saving millions with predictive maintenance. Our conveyor specialists will assess your systems and design a custom monitoring solution.
Frequently Asked Questions
We've got everything you need to get started on your predictive maintenance journey.