Conveyor belt misalignment and roller slippage remain among the most persistent and costly problems in mining and bulk materials handling operations. While these issues are often treated as unavoidable, the real costs can be significant – from lost tonnes and spillage clean-up to premature belt replacement and emergency downtime. Leader in conveyor belt solutions, Tru-Trac continues to focus on helping mines and other operations address these hidden costs directly.

“Conveyors are the arteries of any mine and the costs of inefficiency add up quickly,” Guy Fitt, National Sales Manager at Tru-Trac, says. “When you calculate the production losses, unplanned maintenance and shortened belt life caused by misalignment the savings from properly aligned systems are substantial. Our Apex Series and Grip-Trac range are designed to pay for themselves many times over during the life of the conveyor.”

Belt mistracking is not just a maintenance issue. It can stop production, force emergency shutdowns and drive up operating costs through increased spillage, damage to structure and premature belt wear. The Apex Series trackers have been designed to minimise these risks by providing faster correction and more stable belt alignment, even under fluctuating loads and speeds.

A key feature is the use of adjustable wing rolls on the trough units, giving operators greater control in stabilising the belt path. This innovation reduces the likelihood of spillage and uneven wear while extending the working life of the belt. 

“The Apex design is a rethink of how trackers interact with the belt,” Gerhard Strydom, Technical Manager at Tru-Trac says. “It gives mines far more control in maintaining stability, which directly impacts uptime and cost reduction.”

Tackling slippage 

Slippage between belt and rollers is another major contributor to lost productivity and roller wear. Traditional lagging solutions, often relying on standard rubber or polyurethane compounds, tend to wear quickly in demanding mining conditions. Tru-Trac’s Grip-Trac lagging addresses this through a reinforced rubber compound with greater wear resistance, combined with a tread pattern specifically designed for mining applications.

The pattern improves traction, disperses water and fines and reduces heat build-up and uneven wear. It also acts as a built-in wear indicator, giving maintenance teams a clear signal for timely intervention. “This extends service life and reduces the risk of unexpected failures. It allows mines to plan maintenance, rather than react to breakdowns,” Strydom notes

Built to last

According to Franco Cloete, Manufacturing Manager at Tru-Trac, the commercial value of these products lies as much in the way they are built as in their design. “Every Apex Tracker and roller with Grip-Trac lagging is manufactured to exacting standards in our South African facility,” he says. “We focus heavily on material selection, machining tolerances and assembly processes to ensure consistent reliable performance. Our customers can trust that these are not short term fixes but rather long term solutions.”

Tru-Trac’s belt tracking and lagging technologies have been proven across multiple continents from chrome operations in South Africa to coal mines in South America and iron ore operations in Australia. The company’s global footprint demonstrates that these solutions perform reliably in diverse and demanding environments.

Sidebar / Insert Box 

The Hidden Costs of Mistracking and Slippage

Mistracking

• Lost production tonnes when conveyors are shut down for correction
• Belt edge damage leading to costly premature replacements
• Spillage clean-up including additional labour and equipment time
• Structural damage to idlers, frames and skirting systems

Slippage

• Reduced throughput from poor belt-to-roller traction
• Accelerated wear on rollers and lagging, increasing replacement costs
• Heat build-up that shortens belt and lagging life
• Unplanned downtime when rollers or belts fail unexpectedly

The Bottom Line

Even modest levels of mistracking or slippage can cost mines millions annually in direct and indirect losses. Investing in effective belt tracking and lagging solutions reduces these risks, extends equipment life and delivers measurable savings over the long term.

Lost production is a major direct cost that quarries and mines contend with when a conveyor system goes down. Some of the most common conveyor issues include belt misalignment, material carryback and rip events, amongst others. Drawing on decades of field experience, Tru-Trac’s Douglas van der Westhuizen and Guy Fitt outline some of the best-practice maintenance approaches to keeping conveyors at peak performance. 

One of the most common causes of unscheduled downtime on conveyor systems is belt misalignment which often results in spillage, belt edge damage, damage to the structure, increased power consumption and increased labour costs. According to Guy Fitt, National Sales Manager at Tru-Trac, a specialist provider of conveyor components for the global mining and bulk material handling industries, misaligned belts will ultimately result in lost production, increased operating costs and safety hazards.

Douglas van der Westhuizen, Technical Sales Representative at Tru-Trac, says misaligned belts can also result in environmental issues by increasing material spillage and dust generation which can contaminate nearby ecosystems and water sources, lead to regulatory non-compliance and negatively affect the health of both workers and nearby communities.

Apart from belt misalignment, carryback is another common enemy in conveyor systems. Carryback directly reduces conveyor productivity by creating unscheduled downtime for cleanup, degrading components such as rollers and pulleys and causing material loss and leading to belt tracking issues that necessitate further maintenance. Carryback represents loss of product, which, over time, can add up to significant financial costs, especially in systems handling large volumes,” says Fitt.

Commenting on some of the best-practice maintenance approaches to keeping conveyors at peak performance, Fitt says that continuous inspection is one of the principal approaches to making sure that conveyor systems function optimally. With this approach, minor issues are identified early on before they escalate into major problems that lead to unexpected breakdowns. This minimises unplanned interruptions ensuring that material transport is uninterrupted and production schedules are maintained.

“Constant condition monitoring of conveyor components is one of the best practices in always ensuring correct belt tracking. It is essential to be fully aware of the basic characteristics of the different belt tracking components and for these to be employed correctly,” Van der Westhuizen says, adding that all the structural conveyor components such as pulleys, idlers, take-ups and the supporting structure should always be properly aligned at all times. 

“In fact, these should be the principal areas of concern whenever trying to identify belt tracking problems. All pulleys, snub rollers, troughing and return idlers must be square with the frame parallel to each other, and also be level,” Van der Westhuizen concludes.

Conveyor systems are the backbone of material handling in mines, quarries and bulk processing plants. They move massive volumes of material across long distances and through complex circuits, linking each stage of production. When they operate reliably, they underpin productivity. When they falter, the knock-on effects can halt operations and drive up costs within minutes. Issues such as spillage, carryback, misalignment, premature belt wear and safety incidents can escalate quickly and recovering from them is seldom straightforward.

Against this backdrop, monitoring technologies have developed rapidly over the past decade. What began with basic mechanical indicators has now evolved into sophisticated real-time digital systems capable of providing continuous insight into the performance of the entire conveyor line. This evolution reflects a broader trend across heavy industry with the shift from reactive maintenance to condition-based and predictive strategies. For plant operators, the opportunity lies not simply in collecting more data but in taking an integrated approach that combines mechanical excellence, instrumentation and actionable intelligence. And, critically, the success of that integration is best achieved when supported by a reputable conveyor systems OEM such as Tru-Trac.

The evolution of conveyor monitoring

Monitoring once meant responding to failures after they had already disrupted production. A tripped motor or overheated bearing was the signal that something was wrong and maintenance teams were left scrambling to diagnose and repair the issue. While this reactive model kept belts running, it also locked plants into cycles of unplanned downtime, expensive repairs and higher safety risks.

The first significant change was the move from single-point alarms to broader visibility. Traditional setups might flag motor temperature or belt speed anomalies but these offered only a narrow window into what was happening along the conveyor’s length. Subtle but critical upstream issues – idler failures, belt wander, loading inconsistencies or fugitive material at transfer points – remained invisible until they caused real damage.

Today’s systems integrate multiple data streams across the conveyor line. Belt tracking status, idler vibration, chute and skirt performance, scraper effectiveness, bearing temperatures, power draw, belt thickness and cover wear and load profiles can all be measured and correlated. By piecing these signals together, operators can see how small deviations 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.

Equally important is the trend toward placing monitoring closer to the source of the problem. With the arrival of edge computing, low power devices can now process vibration, thermal and acoustic data directly on idler frames or pulley housings. Instead of waiting for anomalies to surface hours later in the plant’s historian system early signs of wear or friction are flagged immediately, allowing for targeted intervention before a catastrophic failure occurs.

The final, and perhaps most transformative, stage of evolution has been the shift from raw data to actionable intelligence. 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. Integrating these outputs with a plant’s computerised maintenance management system (CMMS) ensures that the right work orders are raised, the correct spares are allocated and technicians arrive on site equipped for the task. This closes the loop from detection to intervention.

Monitoring and mechanical excellence go hand in hand

Despite the sophistication of today’s monitoring technology, the fundamentals of conveyor performance remain mechanical. Belts must track true, loading must be controlled, chutes must flow smoothly and material must be cleaned effectively. If these fundamentals are neglected, even the best monitoring system cannot prevent failures.

This is where a holistic approach comes into play. Hardware such as Tru-Trac belt trackers, primary and secondary scrapers, skirting systems, impact beds and slider cradles continue to form the foundation of reliable conveyor operation. Monitoring enhances these investments by confirming their performance, providing measurable proof of reduced carryback or improved alignment and highlighting when adjustments are required. The fusion of mechanical excellence with digital oversight delivers results that neither approach could achieve alone.

The sustainability and safety dimension

Monitoring also addresses the increasing emphasis on sustainability and safety across mining and materials handling. Conveyor belts consume substantial amounts of energy and misalignment or poor cleaning only increases friction and power draw. By keeping belts centred and return strands clean, operators can achieve measurable energy savings. Extending belt life also reduces the frequency of costly replacements, lowering both material usage and waste.

From an environmental standpoint, reducing spillage and dust directly supports compliance with community and regulatory expectations. Cleaner conveyors mean cleaner plants, safer walkways and reduced reliance on dust suppression systems. Meanwhile, improved diagnostics for pull-cords, emergency stops and guarding systems provide reliable assurance for both employees and regulators that safety measures are in place and functioning as intended.

The business case for integration

The economic benefits of integrated monitoring are clear. Unplanned downtime on a production-critical conveyor can cost tens of thousands of rand per hour. By identifying issues early, plants can act before small problems escalate into major disruptions. Replacing an idler identified as running hot costs little compared to repairing belt edges or recovering from a derailment.

Energy savings are another driver. A belt that is properly aligned and free from excess material runs with lower resistance, drawing less power and reducing stress on motors and drives. Over time, these savings add up to significant reductions in operating costs. Planned maintenance also becomes more efficient. With accurate wear data, spares can be ordered in advance and repairs scheduled during planned shutdowns eliminating the need for costly emergency interventions.

“An integrated approach to monitoring is no longer optional,” Shaun Blumberg, COO of Tru-Trac says. “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.”

Why an OEM partner matters

While the technology is compelling, the true success of any monitoring initiative depends on execution. This is where a reputable OEM such as Tru-Trac makes all the difference.

Firstly, an experienced OEM ensures that monitoring is built on a solid mechanical foundation. Tru-Trac’s belt trackers and cleaning systems are designed to withstand the realities of dust, moisture, misloading, misalignment and heavy duty operating conditions. By addressing the mechanical root causes of issues, they create the conditions in which monitoring can deliver meaningful insights.

Secondly, a trusted OEM provides lifecycle support. From correct commissioning and baseline audits to regular follow-up inspections, an OEM partner ensures that performance standards are maintained and that monitoring data is correctly interpreted. They can validate root causes when alarms are raised and implement permanent fixes rather than leaving operators to battle recurring symptoms.

Thirdly, integration is made practical. Rather than overwhelming plants with excessive sensors and data streams, a partner like Tru-Trac identifies the critical monitoring points that deliver the most value. This ensures that monitoring remains focused, manageable and aligned with operational priorities.

Finally, the reliability of ongoing support cannot be overstated. In regions where logistics and skills shortages can undermine uptime, having a partner who can supply spares, provide training and deliver rapid technical assistance is crucial.

A roadmap to success

For operators looking to embark on this journey, the starting point is a baseline survey of conveyor performance. This assessment highlights the key problem areas – whether mistracking or misalignment on a long overland conveyor, recurring idler failures in a curved section or persistent carryback at a wet transfer point. Mechanical improvements such as upgraded trackers, scrapers or impact systems are implemented first, followed by targeted monitoring to verify performance gains and catch regressions.

Over time, the monitoring architecture can be expanded across the conveyor network. Clear alarm thresholds, direct integration with maintenance systems and monthly review sessions with the OEM partner ensure that monitoring remains relevant and effective.

Conveyor monitoring has progressed far beyond isolated alarms to become a discipline of integration. By combining mechanical excellence, digital intelligence and structured response, operators can reduce downtime, optimise energy consumption, extend asset life and strengthen safety. The role of a reputable OEM such as Tru-Trac is pivotal in making this integration practical and sustainable, ensuring that both hardware and monitoring are designed, implemented and supported to deliver lasting results.

“In an era where efficiency, sustainability and safety are under constant scrutiny, conveyor systems can no longer be managed in silos. 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. 

As the industrial sector undergoes rapid digital transformation, conveyor systems – once regarded as passive infrastructure – are emerging as intelligent data sources. Shaun Blumberg, COO of Tru-Trac, notes that at the centre of this shift is the belt scale.

“This technology was historically focused on weighing material flow but is now transforming into a strategic tool for real-time production visibility, process optimisation and predictive analytics,” he says.

Tru-Trac’s AccuTrac™ AI-enabled Belt Scale platform represents the leading edge of this evolution. Rather than being a retrofit of outdated hardware, it has been designed around the principle that mass flow measurement should be dynamic, contextual and adaptive – not static and reactive. Developed in partnership with Germany-based SHG, the system fundamentally changes the way material flow is measured and managed in industrial environments.

Blumberg explains that conventional belt scales rely on assumptions such as constant belt speed, consistent loading geometry and stable mechanical conditions. In reality, these factors vary: belts stretch, rollers wear unevenly and bulk density fluctuates. This leads to drift in measurement accuracy, frequent recalibrations and reduced confidence in the data.

“The Tru-Trac AccuTrac AI Belt Scale does not rely on static assumptions. Instead, it continuously learns from the conveyor’s operating behaviour and compensates for factors such as drift, vibration and anomalies in the load profile in real time,” Blumberg says.

At the core of the system is a fusion engine that processes inputs including belt speed, load cell output, vibration patterns and environmental conditions. Adaptive algorithms then generate a normalised computational mass flow that more accurately reflects true material movement in demanding environments.

The intelligence is embedded at the edge rather than in a remote server, allowing the system to respond immediately without relying on constant connectivity. This provides operations teams with real-time information and alerts such as early indications of belt tension changes, density fluctuations or idler failures.

“Unlike traditional systems that provide delayed or averaged readings, the Tru-Trac AccuTrac AI Belt Scale delivers contextual data that can be acted upon immediately,” Blumberg adds.

Beyond mass flow measurement, the scale also performs diagnostic functions. It can identify belt slip or stretch, uneven loading, mechanical wear and systemic inconsistencies. By combining these roles into one device, the system reduces the need for additional sensors and infrastructure, simplifying installation and maintenance while lowering potential points of failure.

Calibration, often a challenge with conventional belt scales, is managed through intelligent auto-calibration. The Tru-Trac AccuTrac™ AI Belt Scale system references historical data, production baselines and throughput values to optimise its internal models, improving accuracy with use rather than degrading over time.

The platform is also designed for integration with plant control systems using standard protocols. This allows belt scale data to feed into wider process control loops, such as adjusting feed rates based on downstream capacity or modifying loading geometry in response to live conditions.

In this way, the system moves the belt scale from a static measurement device to an embedded intelligence platform, delivering operational insights across industries such as mining, cement and ports.

“Our AccuTrac AI Belt Scale is designed to adapt continuously to real operating conditions. By embedding machine learning into the system, we can deliver reliable mass flow measurement and diagnostics that support more accurate, efficient and responsive operations,” Blumberg concludes.

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.