Having built a strong customer base across Europe over the past two decades, Tru-Trac Rollers is now strengthening its regional presence with the appointment of three master distributors.

According to Tru-Trac COO Shaun Blumberg, the move aligns with the launch of the company’s new Apex Series Trackers which is the next generation range of belt trackers delivering significant performance benefits and attracting strong interest in international markets, as it has locally.

“We have established a solid foothold in the European market where customers value the quality and dependability of our belt tracking solutions,” says Blumberg. “There is widespread recognition that our products set the benchmark when it comes to addressing the critical challenges of belt misalignment.”

Blumberg notes that the company is excited to reignite its expansion strategy through partnerships with three well-established players in the industry, based in the Netherlands, Spain and the United Kingdom.

In the Netherlands, Cannon Belts will serve as the master distributor and distribution hub for most of Europe and maintain stock levels of Tru-Trac trackers to support efficient supply to the continent. In the UK, the appointed exclusive distributor is Brec, while Masanés Servindustria will handle exclusive distribution of Tru-Trac products across Spain and Portugal.

“These are highly respected companies in their respective regions, each with a strong service centre network to ensure our solutions are fully supported,” says Blumberg. “They have embraced our collaborative approach and we are looking forward to increased market engagement and more frequent visits with resellers as we move ahead.”

The three distributors collaborate closely with preferred partners and resellers, ensuring a consistent supply of products along with active technical support for both the reseller network and end-users.

According to Philipp Starrach, International Sales Manager at Tru-Trac, the company is looking forward to fostering proactive relationships that will enable more advanced levels of technical support and specialised training for its partners.

“In addition to our regular visits to Europe, these distributors will have direct access to the technical expertise at our head office,” says Starrach. He notes that while mining is a declining sector in the region, there are substantial growth opportunities in industries such as quarries, food processing, power generation, ports and recycling.

Blumberg emphasises the ongoing innovation and development within the Tru-Trac Rollers product range, which the company is eager to introduce more broadly to the European market. 

“With a dedicated research and development (R&D) department, we are continually refining and advancing our solutions,” he explains. “In the past two years alone, we have registered no fewer than 10 new patents.”

“With the introduction of our new Apex Series, we are taking deliberate steps to ensure customers across Europe have access to authentic Tru-Trac innovations through our officially appointed distributors,” Blumberg says “In recent years, we have become aware of look-alike products entering the market that attempt to replicate outdated designs of our earlier tracker models. For this reason, we encourage customers to engage directly with our new authorised partners to ensure they receive the latest, patented Tru-Trac technology, backed by factory-trained technical support and full warranty assurance.”

These innovations, designed to enhance both the performance and durability of Tru-Trac’s belt trackers, are built on decades of hands-on experience and rigorous field testing. Blumberg adds that the well-attended bauma 2025 expo in Munich this past April served as the official European launchpad for the company’s new Apex Trough Tracker range.

“We expect the new patented design of our Apex Trough Trackers to gain strong traction through our new distribution networks in Europe, as belt misalignment is a well-known cause of extensive damage and costly downtime,” says Blumberg. “Key enhancements include, among others, high load-bearing cantilevered wing rolls and an optimised in-line idler frame design, which together offer greater stability and improved responsiveness to belt misalignment.”

He points out that the concept of tapered wing rolls was originally pioneered by Tru-Trac, bringing added value to its tracking solutions. The Apex Trough Tracker also features adjustable wing rolls, ranging from 10 to 60 degrees, and boasts a compact footprint – ideal for tight installations beneath conveyor hoods or on tripper cars, with no protruding adjustment bolts.

By taking advantage of Tru-Trac’s holistic conveyor audits, which provide a ‘360-degree’ view to all components of their conveyor systems, mining operations can identify common issues early on and get actionable insights to keep their conveyor belt systems running smoothly. 

Conveyor belt systems are the lifeblood of mining operations, facilitating a constant and uninterrupted flow of materials. Keeping a close eye on the conveyor systems through holistic audits, such as those provided by Tru-Trac, ensures that operations can stay ahead of common issues such as belt misalignment/mistracking, carryback, off-centre loading and spillages, amongst others.  

“Tru-Trac’s conveyor system audits are holistic in their approach, going well beyond the surface-level checks provided by traditional conveyor ‘inspections’ and ‘surveys’,” stresses AJ van Eyssen, Field Service Manager at Tru-Trac. “The audits entail a broader more comprehensive assessment of a conveyor system, encompassing not just the evaluation of potential problems but also the root causes of the issues at hand as well as the provision of recommendations to get to the bottom of the identified issues.”

Using the company’s proprietary digital Conveyor Audit reporting system, Tru-Trac’s highly experienced technicians can send real-time feedback to customers via email. The innovative digital system provides comprehensive insights into the condition and performance of each component in the system, accompanied by photos showing areas of concern, required maintenance and recommendations on how to optimise the entire conveyor system.

This is complemented by the recent integration of the Tru-Trac Rip Prevent+ system, an advanced monitoring technology that analyses data from the conveyor belt using artificial intelligence (AI)-based models and algorithms, which presents an exciting prospect for the audit process. 

The arrival of yet another Tru-Trac innovation, the newly-launched intelligent belt scale, which made its debut at bauma 2025, further provides another important technological tool to the auditing process. It integrates AI-driven continuous calibration check and real-time load cell monitoring for the accurate measurement and detection of tonnes per hour, as well as advanced conveyor belt monitoring by integrating AI-driven analytics with traditional belt scales.

“By identifying and addressing potential issues early on, our holistic conveyor systems’ audits offer significant benefits, including reduced downtime, improved safety outcomes, enhanced operational efficiency and extended conveyor system lifespan,” says Van Eyssen. 

In a recent successful project, the Tru-Trac audit was central to addressing problematic conveyor issues for a Democratic Republic of Congo (DRC) mine. The conveyor system was experiencing impact damage on transfer points due to changing operational parameters such as tonnages and belt speeds. 

“The impact damage was significant in that the client experienced breakdowns after every two weeks. Following a detailed audit, we recommended the changing of impact beds, chutes and conveyor skating to meet the new operational needs. This has successfully addressed the client’s pain points, with the conveyor system having to date gone for six months without any issues,” concludes Van Eyssen.

An iron ore mine in Mauritania was facing considerable safety risk and maintenance costs due to misalignment of its conveyors, until Tru-Trac implemented the solution.

According to Ian King, Sales Manager Africa at Tru-Trac, the customer was visited by Tru-Trac’s representative in West Africa, and an on-site assessment was conducted to analyse the challenges being experienced.

“We recognise that no two conveyors are the same, so it is important to start with a thorough physical inspection,” says King. “This provides the basis for our customised solutions, and allows us to apply the right expertise and equipment.”

This led to the involvement of Tru-Trac’s Technical Sales Engineer, Muller Joubert, who provided further technical assistance in developing the optimal solution. Joubert then spent time at the site, ensuring speedy installation.

“Our on-site survey revealed that several of the mine’s conveyor belts were running into the sides of the structure,” he explains. “This prolonged misalignment had caused significant damage to the conveyor sidewalls. A more serious risk was that this grinding against the structural framework posed a serious safety risk – as the potential build-up of heat in the conveyor belt could escalate into a fire hazard.”

Tru-Trac reported on its findings, highlighting the urgency of the situation to prevent further damage and to allay the safety risk. The company’s recommendation was to install the trusted Tru-Trac V-Return self-alignment trackers, he explains. 

“These innovative solutions are designed to correct belt misalignment automatically, ensuring that the conveyor stays centred even under challenging conditions,” he says. “Even though the conveyor belts had been slightly damaged by the contact with the structures, our solution ensured that the belt could continue operating safely for some time – saving on considerable replacement costs.”

The Tru-Trac trackers’ effect was immediate, he says, aligning the belts centrally within the conveyor structures and preventing any further damage to the belt’s sidewall. As importantly, Tru-Trac’s work on the conveyor system was able to stop spillage from the belt and avoid downtime for maintenance – with both these factors contributing to the mine’s production capability. A total of eight Tru-Trac V-Return trackers were installed across three of the mine’s conveyors, located about 40 metres apart. 

As it was no longer necessary for employees to work next to the conveyor to clean up the spilled material, the operation became safer and more efficient. It was also important to ensure that the trackers could operate sustainably in the harsh desert-like environment with extreme temperatures and frequent dust storms.

“Our trackers are built with sealed mechanisms, ensuring that no dust or debris can compromise their performance,” says Joubert. “This design ensures long-lasting functionality, even in the severe climates and punishing operating conditions so often found on mining sites across Africa and elsewhere.”

He also highlights that the design facilitates quick and hassle-free maintenance to reduce downtime, including a simple roller replacement process and adjustable mounting brackets. 

“Our self-alignment frames are designed for maximum efficiency,” he explains. “The maintenance technician simply loosens two screws on the side of the frame, then releases tension. They drop the frame and remove one more bolt before swopping out the idler and installing a new one.”

This only takes about 20 minutes, which is a dramatic improvement on traditional maintenance times. The result is less standing time and higher productivity, he points out.  

“To customise our solutions, we manufacture our trackers to suit the specific belt width, belt speed and tonnage per hour carried by the conveyor,” says Joubert. “In this case, our trackers were designed for the specific conveyor running between 2,7 metres and 3,2 metres per second.”

He concludes that Tru-Trac’s confidence in its trackers is based on global experience, where they have seen the units performing well after more than seven years. 

“With proper maintenance and regular support, we expect the same outstanding performance from the units we have installed at this mine in Mauritania,” he says. 

In an era where data-driven decisions are critical, Tru-Trac Rollers unveiled its intelligent belt scale system at bauma 2025. Featuring integrated AI-driven continuous calibration checking and real-time load cell monitoring with traditional belt scales, this next-generation solution goes beyond measuring tonnes per hour (tph) to deliver advanced conveyor belt monitoring.

Integrating seamlessly with the award-winning Rip Prevent+ system, which Tru-Trac debuted to its African customers at Electra Mining Africa 2024, this innovation leverages artificial intelligence (AI) to detect anomalies or rip events on all conveyor belt types including steel cord, pipe, and fabric belts.

“This intelligent belt scale sets a new standard,” says Tinus Ludik, Sales Manager – Bulk Materials Handling Division at Tru-Trac. “It is not just technologically advanced but also user-friendly, providing unprecedented data that conventional belt scales simply don’t offer.”

A standout feature is real-time load cell monitoring ensuring millivolt (mV) signals remain within optimal range. Any deviations trigger proactive warnings, allowing for timely intervention and reducing the risk associated with inaccurate or inconsistent readings. By continuously assessing load cell health, the system enhances reliability, repeatability, and accuracy.

Unlike traditional systems that require manual recalibration, Tru-Trac’s intelligent belt scale automatically detects and corrects inaccuracies. Advanced AI algorithms analyse and cross check the belt scale readings against mass flow measurements, identifying deviations and self-adjusting to maintain precise measurements. This eliminates the need for manual intervention, improves reliability and reduces maintenance.

Beyond weighing, the system also monitors conveyor health, ensuring consistent material flow. Continuous mV readings assess belt alignment, flagging potential misalignment caused by off-centre loading.

The belt scale doesn’t just focus on immediate accuracy – it delivers valuable long term operational insights. By tracking key performance indicators (KPIs) in real time, customers gain a deeper understanding of plant efficiency and productivity trends.

“The system’s anomaly detection continuously analyses operational parameters,” adds Ludik. “If any irregularities arise they are flagged instantly, allowing for corrective action before small issues escalate. This real-time oversight fosters constant optimisation and operational excellence.”

With its groundbreaking combination of AI-driven automation, real-time monitoring and advanced diagnostics, Tru-Trac’s intelligent belt scale is set to redefine conveyor performance.

With its range of belt tracking solutions undergoing constant innovation, Tru-Trac has proven its patented Apex Trough Tracker under arduous conditions at the Richards Bay Coal Terminal (RBCT) in KwaZulu-Natal – one of the world’s largest coal export facilities.

Guy Fitt, Sales Manager at Tru-Trac, says that the company had achieved great success with its new Apex Trackers at mining operations and was keen to test the new design in challenging applications on wider and faster belts. RBCT was the ideal site, as it operates some of the most demanding conveyor systems, says Fitt.

“These include 2,2 metre wide steel-cord belts running at 6,7 metres per second and carrying up to 11,000 tonnes of coal per hour,” he says. “We already have some of our older generation trackers on RBCT’s conveyors, and were excited to offer them the advantages of our latest innovation.”

Tru-Trac placed their test unit on one of RBCT’s larger conveyors where the belt was experiencing frequent misalignment, causing damage to the conveyor structure and the belt itself. This was also causing material spillage, leading to production losses. 

Tru-Trac Technical Manager Gerhard Strydom explains that the new Apex design has reduced the amount of steelwork around the tracker’s cradle and uses cantilever wing rolls with an angle adjustment mechanism located below the rollers. This makes the cradle lighter allowing it to react more quickly to movements of the conveyor belt and eliminates protruding adjustment bolts on older models. 

“Even before the end of the initial four week testing phase at RBCT, the Apex Trough Tracker had proven its value by performing exceptionally well in keeping the belt aligned,” says Strydom. “The RBCT team were so impressed with the performance that they placed an order for additional units.”

Another important benefit of the Apex Trough Tracker is its adjustable wing rolls which allows for a range of adjustment from 10 degrees to 60 degrees, making it a versatile retrofit to any conveyor belt. When adjusted to the lowest level the unit is almost flat making storage, handling and installation much safer and quicker – especially when working with heavier belts – as the tracker can be easily slid under the belt. 

“When working with belt widths of between 2,1 metre and 3 metre, the installation process of a conventional tracker may need special lifting equipment, which is not always available at short notice,” he says. “The adjustable wing rolls of the Apex Trough Tracker make for faster installation, so conveyor system uptime is optimised.”

At RBCT, the installation process took a little over an hour, he says, compared to a typical installation time in the industry of between two to three hours. Ease of maintenance has also been improved by the new Apex Trough Tracker design. 

“The maintenance technicians can now simply drop the wing rolls down, slide the tracker out and install the new unit in the same way before adjusting the wing rolls to their operating angles,” he says. 

The Apex Trough Tracker installation at RBCT also demonstrated a further advantage with the new design. Previously it had been necessary to create space in the conveyor hoods or guards to allow for the adjusting rod protruding from the wing rolls. This required permission from the relevant safety personnel as well as some additional metalwork – all of which extended the installation time.

“In our latest innovative design, the cradle no longer requires that section – so it allows a more universal installation ability as there are no restrictions to consider,” says Fitt.

Tru-Trac’s ongoing innovation continues to enhance the performance of the Apex Trough Tracker, according to Fitt. The company is currently commissioning its own unique in-house injection moulded rubber lagging system. In addition to better turnaround times and quality control, this will also allow design improvements to the lagging itself, to deliver better grip and faster reaction times.

“The performance of our latest Apex Trough Tracker at RBCT has definitely opened doors for us,” Fitt says. “It has given us a strong reference point to showcase our capability on high-speed high-tonnage conveyors in international markets – both in coal and hard-rock applications.”

Tru-Trac, a global leader in conveyor belt alignment solutions, has appointed BREC Ltd as its exclusive master distributor in the United Kingdom. This partnership will provide UK-based industries with direct access to Tru-Trac’s advanced belt tracking solutions, supported by local expertise and service.

Since 1995, Tru-Trac has been a pioneer in conveyor belt alignment technology offering patented solutions that enhance efficiency, reduce downtime and lower maintenance costs. Its products are widely used in mining and bulk material handling industries to address belt misalignment challenges effectively.

Jonathan Rogoff, CEO of Tru-Trac, emphasised the strategic importance of the collaboration: “BREC Ltd’s extensive industry expertise and customer-centric approach align with our commitment to delivering innovative and reliable conveyor solutions worldwide.”

With decades of experience in the conveyor sector, BREC Ltd is well-positioned to support Tru-Trac’s expansion in the UK. Steve Perruzza of BREC Ltd highlighted the significance of the alliance: “Partnering with Tru-Trac allows us to bring world class belt tracking solutions to the UK market, enhancing reliability and performance for our customers.”

To ensure broad market coverage and efficient service, BREC Ltd will collaborate with a network of exclusive partners across the UK. A UK-based warehouse will facilitate faster deliveries, manufacturer-backed installation support and ongoing maintenance assistance.

Tru-Trac has installed more belt trackers globally than any other company, offering a product range of over 1,000 variations tailored to diverse operational needs. Its solutions provide a lower total cost of ownership through extended product lifespan and minimal maintenance requirements.

Conveyor belts are crucial components in mining and heavy aggregate handling operations, where efficiency and reliability are paramount. However, these systems often encounter significant challenges, particularly in the loading zones where the impact of falling materials can cause severe belt damage. Tru-Trac’s EXHD Dynamic Impact Idler Bed offers a robust solution designed to protect belts and enhance system reliability in the most demanding applications. 

COO of Tru-Trac, Shaun Blumberg unpacks the design, benefits and broader impact control capabilities of Tru-Trac’s innovative solution.

Blumberg says the challenge of managing impact control in loading zones is a significant one for all materials handling operations. “These transfer zones are the points where materials are introduced onto the belt from chutes, often from considerable heights ranging from 2 metres up to 10 metres. The force of this impact can lead to various issues including belt damage, material spillage and belt misalignment. Insufficient support and impact control ultimately results in frequent maintenance needs, increased downtime and higher operational costs.”

“Traditional impact rollers, while commonly used due to their low cost, often provide inadequate shock absorption particularly in high-drop applications,” he continues. “Furthermore, poorly designed chutes and under-specified impact beds can worsen the problem.”

It is a known fact that improperly engineered loading zones that fail to distribute material evenly or align with the belt’s trajectory create uneven wear, and this significantly increases the likelihood of belt damage.

According to Blumberg, Tru-Trac’s EXHD Dynamic Impact Idler Bed represents a unique and significant advancement in addressing these issues. Specifically engineered for applications with drop heights between 2 metres and 10 metres, this system is designed to absorb heavy aggregate impacts safely, preventing belt damage and extending the belt’s life. 

The Tru-Trac EXHD Dynamic Impact Idler Bed combines dynamically adjusting impact idlers with robust shock-absorbing springs to provide superior impact control.

The impact idlers in the Tru-Trac EXHD system oscillate to adjust dynamically to the load, significantly reducing the force transmitted to the belt. This movement allows the system to absorb and dissipate impact energy more effectively than static systems. The heavy duty springs enhance this absorption, capable of handling loads up to 11.4 tons, working in tandem with the idlers to manage high impact conditions effectively. This advanced design ensures minimal stress on the belt, preventing damage and enhancing durability.

Blumberg says that Tru-Trac offers a range of impact control solutions tailored to specific application requirements ensuring that conveyor systems are protected from various types of impact forces. This includes standard impact beds, impact rollers and slider frames; all of which are engineered for easy installation and minimal maintenance.

Tru-Trac’s capabilities also extend to addressing dust and spillage around the impact or loading zone. “Proper dust and spillage control are essential for maintaining a clean and efficient conveyor environment and our solutions help to minimise material loss and prevent the accumulation of debris which can lead to additional wear and operational inefficiencies,” he says. 

A recent case study from a copper mine in the DRC highlights the effectiveness of the Tru-Trac EXHD Dynamic Impact Idler Bed. The mine faced extreme challenges with its conveyor system, where high impact loads in the loading zone frequently caused belt damage, leading to significant downtime and maintenance costs. The existing impact system, which used traditional rollers, proved inadequate for handling the high drop heights and abrasive materials. 

“Our local team conducted a comprehensive site assessment, collecting the necessary data and analysing various factors such as material properties, drop heights, existing system configurations and operational challenges,” Blumberg says. “This detailed evaluation included observing the wear patterns on the existing conveyor belt, identifying the sources and magnitude of impact forces and assessing the overall condition of the loading zones.” 

“By gathering the necessary information first hand and gaining a thorough understanding of the specific conditions and requirements, our engineering team could offer a solution that would effectively address the unique challenges faced by the site and this saw the installation of our Tru-Trac EXHD Dynamic Impact Idler Bed,” he says. 

In this application, the system’s oscillating idlers and heavy duty springs work in tandem to absorb and disperse the severe impacts. The oscillating idlers dynamically adjust to the load, allowing them to move with the material as it falls onto the belt. This dynamic adjustment significantly reduces the direct force transmitted to the belt, preventing sudden shocks that can cause damage. The heavy duty springs complement this action by providing robust shock absorption, further minimising stress on the belt. 

“Together, these components ensure that the belt remains aligned, preventing issues such as misalignment, tearing and edge wear. By maintaining proper alignment and reducing impact related damage the system increases the belt’s longevity and reliability and has ultimately led to reduced maintenance costs and increased uptime at this customer,” Blumberg says. 

It is apparent that the broader impact of poorly designed loading zones cannot be underestimated. Inadequate impact protection can lead to increased spillage, belt misalignment and structural damage to the conveyor system. Misalignment causes the belt to drift leading to additional wear on the edges and other components which, in turn, increases maintenance requirements and potential operational downtime. Chutes that are not properly aligned with the conveyor can misdirect materials, creating irregular impact points and causing excessive localised stress on the belt. This can result in belt failure and significant operational disruptions. 

“Tru-Trac’s EXHD Dynamic Impact Idler Bed represents a significant advancement in conveyor belt protection, effectively addressing the complex challenges of impact control in loading zones and we believe that investing in high quality impact beds and ensuring proper chute design is crucial for maintaining efficient and reliable conveyor operations,” Blumberg concludes. 

To help bulk material handling operations address conveyor belt misalignments, a common issue in quarrying and mining, Tru-Trac Rollers has introduced its Apex Taper Trough Tracker, the next leap forward in belt tracking technology. 

That conveyor belt mistracking is one of the most common causes of unscheduled downtime in conveyor systems is no overstatement. Belt misalignment causes spillage, belt edge damage, damage to the structure, increased power consumption and increased labour costs. Misaligned belts will ultimately result in lost production, increased operating costs and safety hazards.

To help mining and materials handling operations prevent this from happening, Tru-Trac Rollers has brought to market its innovative Apex Taper Trough Tracker, the ultimate misalignment solution for conveyor belt systems. Available in four types – Standard, HD, XHD and EXHD – the range ushers in a new era with an array of innovative features. Key among them is the combination of the tapers and in-line idler configuration mounted on a unique centre pivot, providing fast reactive and continuous belt tracking in all conditions.

“The pivot system has been enhanced significantly. The upgraded system now includes enhancements for durability and better protection against dust, especially in fine dust environments,” explains Douglas van der Westhuizen, Technical Sales Representative at Tru-Trac Rollers. 

With its compact design, the Apex Taper Trough Tracker can be installed effortlessly in tight spaces, such as under hoods or on tripper cars. The new cantilevered wing roll and cradle replace the previous design’s protruding adjustment bolts, eliminating space constraints and potential safety hazards. Adjustments are now quick and straightforward, allowing for easy angle setting of the wing rollers.

“The Apex Taper Trough Tracker’s inline taper wing rollers are designed for compatibility with trough angles up to 60 degrees and can flatten as low as 10 degrees for easy installation and transportation. This is a significant upgrade to the maximum 50 degrees trough angle on the previous system,” says Guy Fitt, National Sales Manager at Tru-Trac Rollers. 

The improved custom-compounded GRIP-TRAC™ rubber lagging and patented tread pattern on wing rolls offer enhanced traction and tracking performance and extended working life of the replaceable wing rolls, further reducing total cost of ownership.

Increased responsiveness is yet another key benefit of the new Apex Taper Trough Tracker. The optimised centre of gravity and weight distribution offers improved stability, control and balance. This enhances sensitivity to belt misalignment and tracking performance by increasing efficiency and responsiveness.

“We used Electra Mining Africa last year to showcase how the new Apex Taper Trough Tracker ushers in a new era in belt tracking technology and several clients who visited our stand were thrilled to witness the outstanding capabilities of this groundbreaking technology. Operations that are already running the system have also expressed great satisfaction with the exceptional performance of the Apex Taper Trough Tracker,” concludes Fitt.

The accurate measurement of bulk materials is essential across industries like mining, processing plants and aggregate handling. Tru-Trac’s Belt Scale Systems are at the forefront of delivering innovative technology that ensures precise and reliable measurements, setting new benchmarks in conveyor belt efficiency and operational control.

In industries reliant on efficient material handling, maintaining precise weighing systems is paramount for optimising production processes and managing inventory effectively. Tru-Trac Belt Scale Systems offer unparalleled accuracy and reliability, even in challenging environments. They provide crucial data for informed decision-making and operational streamlining.

Traditional belt scales often struggle in harsh industrial settings, where conditions can lead to inaccuracies and frequent recalibrations. Tru-Trac’s advanced belt scale systems overcome these challenges by integrating state-of-the-art technology with robust design principles, ensuring consistent performance and precision.

A key component to Tru-Trac’s Belt Scale Systems are high-precision load cells that deliver accurate measurements essential for effective material handling. These systems feature innovative digitisation located close to the load cells and carriage, eliminating the need for traditional junction boxes. This design enhances signal integrity, ensuring precise data transmission and reliable weighing results critical for optimal operational control.

Tinus Ludik, BMH Sales Manager at Tru-Trac, highlights the system’s design advantages: “Our belt scales leverage advanced digitisation to maintain high signal integrity and accuracy, minimising errors and delivering consistent, precise measurements crucial for efficient material handling.”

Tru-Trac’s Belt Scales are engineered for seamless integration into both new and existing conveyor systems. Their flexibility allows them to meet diverse operational requirements, from single conveyor installations to complex multi-scale setups. The user-friendly human-machine interface (HMI) with a touch screen provides intuitive controls, making the system accessible even in harsh industrial conditions.

The belt scales support multiple communication protocols through various integrators, ensuring compatibility with different control systems. This flexibility simplifies integration and facilitates efficient data management, enhancing overall system efficiency and reliability.

An optional feature of Tru-Trac’s Belt Scale Systems is the Remote Monitoring System (RMS) offering real-time access to operational data and remote calibration capabilities. This system minimises the need for on-site maintenance, allowing users to monitor their systems from any networked device. “Our RMS provides real-time data access and remote calibration, reducing maintenance needs and offering continuous operational oversight,” Ludik says. 

At a major aggregate handling facility, Tru-Trac’s Belt Scale System delivered transformative results. Faced with accuracy and reliability challenges in their existing systems, the facility experienced operational inefficiencies and increased costs. Tru-Trac’s advanced system featuring high-precision load cells and enhanced digitisation provided accurate reliable measurements, improving inventory management and production control.

Ludik says that implementing the Tru-Trac Belt Scale System at the aggregate facility demonstrated its effectiveness in providing precise measurements, even in challenging environments. The accurate data optimised production processes and reduced operational inefficiencies. 

“The aggregate facility witnessed significant improvements in weighing accuracy and operational efficiency. Our technology proved capable of handling demanding conditions while delivering the precision needed to enhance performance,” he says. 

Tru-Trac’s capabilities extend beyond accurate weighing to include comprehensive conveyor solutions such as belt cleaners and impact and spillage control around loading zones. These systems integrate seamlessly with Tru-Trac’s Belt Scale Systems, ensuring cohesive management of material handling processes and reducing material loss.

By combining Tru-Trac’s belt scales with Rip Detection and Metal Detector solutions, operators achieve a streamlined material handling process, minimizing maintenance and optimizing performance.

Tru-Trac’s Belt Scale Systems represent a breakthrough in conveyor weighing technology, offering high-precision load cells, advanced digitization, and real-time monitoring capabilities. These systems deliver the accuracy and reliability needed for efficient bulk material handling, making them ideal for both new installations and retrofits.

Effective conveyor belt tracking is essential for maintaining operational efficiency and preventing issues on conveyor belt systems and belt trackers, although seemingly small components, play an important role in maintaining the alignment and smooth operation of conveyor belts. 

According to Gerhard Strydom, Technical Product Manager at Tru-Trac, a leading authority in conveyor technology, a one-size-fits-all approach does not apply to belt tracking solutions. Proper specification and installation are critical to achieving the expected performance and longevity.

Strydom explains that key considerations in specifying belt trackers include belt speed, width, tension and tonnage per hour on the loading side. He emphasises the importance of gathering accurate application data to ensure the optimal solution is installed. 

“Environmental factors such as dust, moisture and wind as well as the type of belt material – whether it is a steel core or solid woven belt – further influence the choice,” he explains. “Additionally, any specific challenges that the customer has experienced with the conveyor system need to be prioritised in the solution.”

Tru-Trac’s approach to belt tracking involves comprehensive assessment, preferably on-site, starting from the tail section of the conveyor. This method allows the company’s in-house specialists or trained distribution partners to gather operational data and understand historical challenges directly from belt attendants. “We prefer to base our assessment on an on-site walking inspection of the conveyor,” Strydom says. This meticulous approach ensures that the trackers are tailored to the specific conditions and requirements of each conveyor system.

Tru-Trac offers a wide range of belt trackers, from entry-level units for the troughing or return side of conveyors to heavy duty applications capable of handling belt speeds up to 10 metres per second. The success of their design and technology has been proven across various industrial applications. 

For instance, a South African platinum operation facing significant spillage and belt edge damage due to severe misalignment benefited immensely from Tru-Trac’s expertise. The installation of a Tru-Trac taper trough tracker after the loading zone and a dual return tracker before the tail pulley resolved the alignment issues, allowing the belt to operate for almost four years before requiring replacement.

A recent project at a prominent copper mine in Zambia demonstrated how changing conditions can affect the suitability and lifespan of a specified belt tracker. Ian King, Africa Sales Manager at Tru-Trac, recounts the challenges faced when the conveyor system experienced severe mistracking issues in the loading zone after production levels were increased without notification. 

The high tonnage belt began to make contact with the structure, causing significant edge fraying and tearing, which reduced the usable width of the belt and compromised its overall performance. The existing alignment system was not robust enough to manage the severity of the mistracking, leading to downtime for belt and structural repairs, increased operational costs and a risk of fire.

To address these challenges, Tru-Trac local technicians conducted a thorough inspection of the conveyor system and installed the Tru-Trac Apex Tracking System. This solution included the installation of both trough side and return side trackers, strategically positioned to maintain belt alignment and prevent edge damage. 

The trough side apex trough tracker was installed just after the loading zone, while the return side dual return tracker was placed near the tail pulley. These trackers engaged immediately on start-up, steering the belt to the centre position and continuously ensuring alignment thereafter. King says that the customer was extremely pleased with the performance of Tru-Trac’s equipment, and that the aligned and protected belt not only enhanced safety but also improved our operational efficiency. The mine has now standardised on Tru-Trac belt misalignment solutions for other sections of the mine.

While Tru-Trac’s belt trackers are known for their robust design and even come with a lifetime warranty on some components, other aspects of the conveyor must be monitored carefully for optimal performance. Strydom highlights the importance of conveyor scrapers, which, if not fully functional, can impact the performance of the tracker. 

“If the belt scraper is not working well, this can allow material to be carried back on the return side of the conveyor belt,” he says. “This material builds up and can compromise the performance and functioning of a tracker.”

As the costliest element of the conveyor system, the belt itself can be severely damaged by misalignment, often starting with wear on the edges. This leads to ply separation, allowing moisture to penetrate the belt carcass and degrade its integrity, usually resulting in premature failure. The acceptance of high performance belt trackers as a standard feature on a conveyor system has grown over the years, King notes. These units are often installed at the outset of a project rather than only after belt misalignment has been identified as a recurring issue. This proactive practice recognises the costly impact of conveyor system downtime, which can potentially bring all or part of an operation to a standstill.

“The adoption of advanced belt tracking solutions reflects the industry’s recognition of their role in mitigating downtime and enhancing overall conveyor performance. We believe that Tru-Trac’s tailored approach, comprehensive assessments and high quality products ensure that our belt tracking solutions align with operational demands and environmental conditions, sustaining efficiency and productivity in diverse industrial applications,” King says. 

“As conveyor systems continue to evolve, Tru-Trac will remain at the forefront, delivering reliable solutions that uphold the integrity and functionality of these essential systems,” he concludes.