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. 

Maintaining its market leading position in conveyor solutions, Tru-Trac unveiled an innovative system at Electra Mining Africa which will have a major impact on all operations that use conveyor belts.

Early detection of potential issues on conveyor systems is crucial in mining and other materials handling applications and to address this need, Tru-Trac introduced the Rip Prevent+ system. This cutting-edge monitoring technology, which is set to disrupt the sector, identifies and mitigates conveyor belt anomalies and damages, thereby minimising downtime and enhancing efficiency and productivity.

The Tru-Trac Rip Prevent+ system, now available in Africa, allows mines to optimise their conveyor lines’ performance by preventing costly interruptions due to rip events. The system has already proven effective in global mining operations and was debuted locally at Electra Mining Africa.

Using a data-driven model and artificial intelligence (AI), the Tru-Trac Rip Prevent+ system can detect anomalies or rip events on any conveyor belt type, including metal cord, pipe and fabric belts.

The innovative system was designed to avoid the need for sensor elements inside the belt, making it versatile for all conveyor systems. The Rip Prevent+ system analyses data from the conveyor belt using an AI-based model. This AI, combined with an innovative algorithm, detects anomalies and rips, generating data and signals that allow customers to stop the conveyor line before significant damage occurs. The system’s model computes data 50 times per second and can generate a signal to the Programmable Logic Controller (PLC) within 0.2 seconds, reducing the impact of rip events.

By stopping the conveyor belt when a possible rip event is detected, the system minimises associated damage, potentially saving millions in downtime, belt replacement, and cleanup costs. The system’s data-driven model offers significant advantages over inductive, magnetic and laser-based systems including reduced wear risk, suitability for all conveyor types and lower investment costs.

The Rip Prevent+ system is web-based and accessible via an Ethernet network connection, featuring a user-friendly interface with a dashboard displaying key information. Additionally, the system incorporates several functions beyond rip detection, including mass flow calculation, condition monitoring, drive or motor monitoring, energy efficiency and electrical network analysis, aligning with predictive maintenance strategies.

The Rip Prevent+ system is also easy to install, requiring only 30 minutes to an hour, with minimal downtime for electrical connections. Commissioning the system can be completed within two to five hours, depending on preparatory work and available system parameters.

Notably, Rip Prevent+ is the first rip detection system offering a more affordable alternative through a subscription model that minimises initial capital investment.

Following worrying discrepancies in the monitoring of production output, sales and inventory, a belt scale from Tru-Trac is winning the day for KwaZulu-Natal-based AfriSam Coedmore Quarry. With groundbreaking static calibration accuracy error levels as low as 0,06%, the belt scale provides reliable data for sound decision-making.

Over the years, AfriSam Coedmore Quarry has had issues with stock capturing and evaluation. “Accurately measuring production, sales and stock levels is critical for effective management and efficient operations,” says Lloyd Maringa, Works Manager at AfriSam Coedmore Quarry.

“Traditionally, we conduct quarterly stockpile surveys though an independent third-party to gauge the levels of stock on the ground. It was during these surveys that we would always encounter huge discrepancies between what we had produced, what would have been sold and what should have been on the floor.”

In some instances, the variations were as high as 70 000 tonnes (t). In the quest to resolve the problem, the operation resorted to monthly surveys instead of the usual quarterly routines. The more frequent surveys, however, did not yield different results. Further investigations eventually pinpointed issues with the existing belt scale between the intermediate stockpile and the secondary crusher. Despite several interventions, including regular calibrations by the supplier and even the installation of a second belt scale, the challenge persisted.

“We therefore went into the market for a new belt scale supplier,” explains Dustin Naidoo, Maintenance Superintendent at AfriSam Coedmore Quarry. “Tru-Trac proposed a proof-of-concept approach, whereby they installed a belt scale on a trial basis for a month. Upon evaluation of the results, we were impressed by the high levels of accuracy.”

Since the installation of the Tru-Trac belt scale, the stock management and evaluation problems are a thing of the past. “We have now reverted to the usual quarterly stockpile surveys, which saves us both time and money,” says Maringa.

Tru-Trac’s flagship TTR FI-4 belt scale system installed at AfriSam Coedmore uses a fully floating pivotless weigh frame supported by four load cells, making it ideal for high-precision applications. It is a simple and extremely accurate system engineered to produce precise data. With a proven accuracy margin under 0,1%, the belt scale sets industry standards in metallurgical accounting.

“In addition to the accuracy of the technology, we are equally impressed by the service provided by Tru-Trac. Although they taught us to do in-house calibrations, a technician visits our site every month. Choosing Tru-Trac has proven to be one of the best business decisions we have made in recent times,” concludes Naidoo.

When margins are squeezed by lower commodity prices, mines must secure the productivity and efficiency of key functions like conveyors – and Tru-Trac Rollers can assist in doing just that.

“Turmoil in the mining sector is leading to lay-offs and pressure on capital budgets,” says Guy Fitt, National Sales Manager at Tru-Trac Rollers. “Both these factors can reduce the reliability of conveyor systems, at a time when the mine’s productivity levels can least afford it. As a leading original equipment manufacturer (OEM) in this field, Tru-Trac provides flexible maintenance and support services to solve this dilemma.”

Fitt emphasises that conveyor systems are the life blood of any mine or plant, so it is critical to ensure adequate maintenance or the whole operation’s productivity will suffer. Where mines are under financial pressure, Tru-Trac can step in to take the load off certain personnel, freeing them to focus on other critical areas of the mine.

“We can assume responsibility for a range of tasks from checking and changing idlers to the cleaning of belt scrapers and maintaining belt trackers,” he says. “These are vital to avoid downtime, but can go ignored if mine staff are too thinly spread – with dire consequences for uptime and production.”

Tru-Trac Technical Product Manager Gerhard Strydom notes that mines sometimes even need to do without their usual complement of artisans and assistants during difficult times. The company’s support teams are ideally suited to step in and assist, says Strydom, as they are well trained in general maintenance of conveyor systems while also being familiar with the mining industry.

It is clear that the market recognises the value of Tru-Trac’s support, he points out, as a number of them have been customers for over 12 years. Many of these relationships have evolved into maintenance contracts with a team dedicated to conveyor maintenance on site for a specified time. Fitt explains that the work which these teams perform during these hours, while focused on conveyor maintenance, is not limited to only Tru-Trac’s products, but rather focuses on overall conveyor maintenance, performance and safety.

“The benefit of well trained and experienced conveyor service and maintenance teams ensure that belts are well maintained, and the necessary preventative maintenance work is completed, contributing to our customers’ other related requirements wherever possible,” he says.

As the company’s national footprint has expanded, it has recruited and trained technicians from areas close to the customer base, facilitating the upskilling within local communities. These individuals require comprehensive training to ensure skills and an in-depth knowledge of Tru-Trac products. Training is done either at head office or at the branches.

Tru-Trac’s aim is to improve the efficiency of the customer’s conveyor system, says Strydom, which means giving all aspects of this equipment the attention they deserve. He warns that the conveyors on many mines are only attended to when there is a breakdown.

“While some customers request that we train their staff in equipment maintenance if they have enough personnel, it is increasingly common for mines to keep us on site as the specialist OEM, allowing their artisans to concentrate on core mining activities,” he says.

“The advantage of a maintenance contract is that the mine has the comfort of knowing a specialist is on site, giving this essential system all the necessary attention,” he says. “We conduct regular surveys of belt tonnages, belt speeds and ground conditions, for instance, to check that the trackers and other equipment are performing to our standards.”

It is this ‘extra pair of eyes’ that allows the uptime of conveyor systems to be optimised. Tru-Trac has developed relationships of trust with longstanding customers through its ability to identify issues and bring these to the attention of management. In one instance, the team identified a problem where a customer’s run-of-mine belt was lifting off the structure completely – causing misalignment, loss of product and damage to the belt itself. After reporting the issue, Tru-Trac was able to design, engineer and install a solution to the customer’s satisfaction.

“We have skilled and experienced teams close to customers, who we continuously upskill through our training resources,” says Fitt. “This expertise is available to the mining sector, and has proven to have a marked impact on conveyor uptime and productivity.”

Conveyor belt scales are indispensable components for measuring bulk materials in mining and industrial operations – but their value is compromised if accuracy is poor.

“The ability to measure moving material in real time allows mines to monitor their mass balance and to ensure that the correct volumes are being fed by conveyor into various plant functions, for instance,” says Tinus Ludik, Sales Manager Bulk Materials Handling at Tru-Trac. “Operating under demanding conditions, belt scales must ideally remain not only functional but accurate – which is why we have developed solutions which stand out in terms of quality, repeatability and accuracy.”

Ludik notes that belt scales can also become less accurate over time, so there needs to be regular calibration to ensure that any extreme deviation is quickly rectified. When accuracy errors are high, a plant is prevented from operating at optimal productivity as plant operators can never be sure whether they are overloading critical equipment like mills. 

“To avoid these risks, Tru-Trac’s range of belt scales are designed and manufactured to the highest standards, so operators can be confident of the readings they receive,” he explains. “This allows plants to operate at their highest efficiencies, with reliable data being provided for decision making.”

The company’s offering ranges from its TTR SI-2 single idler belt scale system to the TTR DI-4 dual idler belt scale system, and on to the top of the range TTR FI-4 belt scale system with a four-load cell design. Equipped with high precision load cells and a fully floating weigh frame, the mid-range TTR DI-4 achieves accuracy errors of below 0,25%. It integrates seamlessly with Tru-Trac’s remote monitoring system.

“Our flagship TTR FI-4 system boasts a fully floating pivotless weigh frame and four-load cell design, making it ideal for critical control point applications and high-precision demands,” he explains. “With an achievable accuracy margin under 0,1%, it sets industry standards in metallurgical accounting.”

Every application requires its own assessment and solution, says Ludik, starting with the belt speed. He points out that faster speeds give the belt scale less time to assess the weight on the belt, and it is best to allow at least one second to achieve a reliable reading. The company’s rapidly growing installed base of belt scales includes installations at large plants with up to 150 belts in a single operation. 

Demand has already extended well beyond the borders of South Africa, with Tru-Trac belt scales at work in Namibia, Zimbabwe, Mali and Tanzania – and sales increasing to Zambia, Botswana, Mozambique and Ghana. International distribution of scales in regions such as Southeast Asia is also demonstrating promising demand for the Tru-Trac range of belt scales.

The robust and shock absorbent load cells are locally produced, and Tru-Trac holds extensive stock to ensure quick replacement whenever necessary. The integrator for each unit is well protected within a stainless steel housing for corrosive environments. Enclosures are designed to ingress protection (IP) ratings of 65 or higher to keep out dust and moisture.

“With our focus on quality, we are also excited to be underway with the process of accrediting our belt scales with the South African National Accreditation System (SANAS) through the National Regulator for Compulsory Specifications (NRCS),” he says. 

He emphasises that regular maintenance and calibration is vital, and Tru-Trac offers support to do this, as well as guidance on the steps and intervals. Weekly or fortnightly calibration is advised, and the company provides the necessary training to staff on site wherever required. The well equipped training facility at Tru-Trac’s factory near Pretoria includes an operational 18 m conveyor on which its belt scales are installed. Specialised training is supplied to customers by the company’s experienced team. 

“We have all the communication protocols available, so our belt scales can link to the mine’s PLC or SCADA systems,” he notes. “This allows seamless monitoring of key indicators such as totalised weight, belt speeds, load cell voltages, tonnes per hour and kilograms per metre; the data that can be reflected is also highly customisable according to the customer’s needs.”

Conveyor belt scales are indispensable components for measuring bulk materials in mining and industrial operations – but their value is compromised if accuracy is poor.

“The ability to measure moving material in real time allows mines to monitor their mass balance and to ensure that the correct volumes are being fed by conveyor into various plant functions, for instance,” says Tinus Ludik, Sales Manager Bulk Materials Handling at Tru-Trac. “Operating under demanding conditions, belt scales must ideally remain not only functional but accurate – which is why we have developed solutions which stand out in terms of quality, repeatability and accuracy.”

Ludik notes that belt scales can also become less accurate over time, so there needs to be regular calibration to ensure that any extreme deviation is quickly rectified. When accuracy errors are high, a plant is prevented from operating at optimal productivity as plant operators can never be sure whether they are overloading critical equipment like mills. 

“To avoid these risks, Tru-Trac’s range of belt scales are designed and manufactured to the highest standards, so operators can be confident of the readings they receive,” he explains. “This allows plants to operate at their highest efficiencies, with reliable data being provided for decision making.”

The company’s offering ranges from its TTR SI-2 single idler belt scale system to the TTR DI-4 dual idler belt scale system, and on to the top of the range TTR FI-4 belt scale system with a four-load cell design. Equipped with high precision load cells and a fully floating weigh frame, the mid-range TTR DI-4 achieves accuracy errors of below 0,25%. It integrates seamlessly with Tru-Trac’s remote monitoring system.

“Our flagship TTR FI-4 system boasts a fully floating pivotless weigh frame and four-load cell design, making it ideal for critical control point applications and high-precision demands,” he explains. “With an achievable accuracy margin under 0,1%, it sets industry standards in metallurgical accounting.”

Every application requires its own assessment and solution, says Ludik, starting with the belt speed. He points out that faster speeds give the belt scale less time to assess the weight on the belt, and it is best to allow at least one second to achieve a reliable reading. The company’s rapidly growing installed base of belt scales includes installations at large plants with up to 150 belts in a single operation. 

Demand has already extended well beyond the borders of South Africa, with Tru-Trac belt scales at work in Namibia, Zimbabwe, Mali and Tanzania – and sales increasing to Zambia, Botswana, Mozambique and Ghana. International distribution of scales in regions such as Southeast Asia is also demonstrating promising demand for the Tru-Trac range of belt scales.

The robust and shock absorbent load cells are locally produced, and Tru-Trac holds extensive stock to ensure quick replacement whenever necessary. The integrator for each unit is well protected within a stainless steel housing for corrosive environments. Enclosures are designed to ingress protection (IP) ratings of 65 or higher to keep out dust and moisture.

“With our focus on quality, we are also excited to be underway with the process of accrediting our belt scales with the South African National Accreditation System (SANAS) through the National Regulator for Compulsory Specifications (NRCS),” he says. 

He emphasises that regular maintenance and calibration is vital, and Tru-Trac offers support to do this, as well as guidance on the steps and intervals. Weekly or fortnightly calibration is advised, and the company provides the necessary training to staff on site wherever required. The well equipped training facility at Tru-Trac’s factory near Pretoria includes an operational 18 m conveyor on which its belt scales are installed. Specialised training is supplied to customers by the company’s experienced team. 

“We have all the communication protocols available, so our belt scales can link to the mine’s PLC or SCADA systems,” he notes. “This allows seamless monitoring of key indicators such as totalised weight, belt speeds, load cell voltages, tonnes per hour and kilograms per metre; the data that can be reflected is also highly customisable according to the customer’s needs.”

As global leaders in solutions for conveyor belt misalignment, Tru-Trac will excite visitors to Electra Mining Africa this year with a whole new range of belt trackers among its innovative offerings. The latest range is the outcome of two years of design, development and testing, according to Tru-Trac Chief Operating Officer Shaun Blumberg. 

The stand also features Tru-Trac’s robust range of belt scales, engineered for precision and dependability, and a pioneering step into the future with a cutting edge belt rip detection system.

“With our belt trackers setting the gold standard for effective belt alignment, the new range builds on the success of its predecessors, elevating them to an entirely new level of performance,” says Blumberg. “We’ve introduced exciting enhancements to our belt trackers, bringing notable improvements in performance and reliability.”

Tru-Trac has built a formidable name for itself over the past three decades, extending its footprint and sales not only across Africa but worldwide. Blumberg highlights that Electra Mining Africa is another valuable opportunity to meet face to face with visitors from many African countries where Tru-Trac still has further potential to contribute to efficient and productive mining operations through improved conveyor system performance. 

“We are excited to present our extensive range of conveyor components at our stand, offering a complete view of our innovative solutions,” he says. “Visitors will have the opportunity to explore the design and functionality that contribute to our products’ success globally.”

A real drawcard for visitors will be Tru-Trac’s investment in Internet of Things (IOT) technology, specifically the integration of digital solutions to facilitate predictive maintenance through real-time monitoring of equipment. 

“The mining sector is increasingly turning to IoT to refine data collection and analytics, enhancing overall efficiency. Our IoT-enabled conveyor solutions offer predictive and preventative maintenance, reducing downtime and enhancing productivity,” he says. 

Demonstrating this commitment will be at least two product offerings on show at Electra Mining Africa: the company’s proven range of belt scales and a revolutionary new belt rip detection system that promises to be a real disruptor in the sector. 

“Our belt scales have seen considerable success since their launch two years ago,” he says. “These are critical components in any bulk materials handling operation, providing both accurate and repeatable data on throughput and production.”

Working with specialist design engineers, Tru-Trac has achieved a best-in-class product range which now also boasts a digital reporting platform that allows remote monitoring and reporting. Response from customers in the field has been enthusiastic, says Blumberg, and considerable interest is expected at Electra Mining Africa. 

“Tru-Trac Rip Prevent+, our next-generation belt rip detection system, is set to impress and generate strong interest,” he continues. “This is a disruptive solution which we are launching in Africa with our partners, SHG of Germany. Using artificial intelligence to monitor power consumption for anomalies, this technology gives early warnings of potential belt rips, enabling operators to react swiftly and prevent damage.”

Visit Tru-Trac in Hall 6 Stand F16

Solid demand growth has led conveyor solutions innovator Tru-Trac to upgrade and expand its facilities at Richards Bay and Middelburg. 

“These strategic expansions are part of enhancing our branch infrastructure across major mining regions in South Africa,” says Guy Fitt, Tru-Trac’s National Sales Manager. “We are intensifying our direct support to customers in various ways including product supply, technical support and our installation and maintenance services for conveyor systems.”

Fitt highlights that the strengthening of the company’s presence in KwaZulu-Natal and Mpumalanga goes hand-in-hand with similar initiatives at established locations such as Rustenburg, Kuruman, Cape Town and Steelpoort, as well as its headquarters in Centurion. Distributors are also being appointed in strategic areas, to further enhance responsiveness to customers’ dynamic needs. Tru-Trac is active in a range of sectors including mining, cement and aggregate production.

“Our operational upgrades include expanded warehouse capabilities, training facilities and advanced service centres, designed to meet the growing demands of our customers,” he explains. “These facilities will offer our complete product lines including our high performance belt scrapers, belt alignment systems, belt scales and maintenance services – all designed to minimise downtime and extend equipment life.”

Tru-Trac strategically chose its location in Richards Bay to optimise support for the port and shipping industries, improving material handling processes with its specialised equipment. Meanwhile, its expanded Middelburg facility will focus on serving the region’s coal and cement industries with local support and rapid response times.

“A key component of our regional strategy is the addition of skilled personnel,” says Fitt. “We have doubled our team of service technicians and engineers in these regions, ensuring that expert advice and maintenance experience are readily available.” 

Both areas are led by experienced personnel supported by a dedicated customer service and technical support team that is committed to excellence. 

“With these upgrades, Tru-Trac is not just investing in infrastructure; we are investing in our customers’ success,” says Fitt. “Our enhanced facilities and expanded team allow us to deliver unparalleled service and innovative solutions that our clients have come to rely on.”

As part of its commitment to local communities and sustainable practices, Tru-Trac is also implementing training initiatives at both the Richards Bay and Middelburg sites. This will enhance skills development through partnerships with local communities – facilitating job creation on new maintenance contracts.

“Tru-Trac’s upgraded facilities are operational and ready to support the needs of current and future clients,” concludes Fitt.