AI-powered laser and vision system for real-time belt health monitoring and risk detection.

Why is effective monitoring essential?

Conveyor belts are a critical component of modern material handling systems. They enable the safe and continuous transport of bulk materials across industrial facilities. Composed of belts, rollers, motors, and tensioning systems, these systems are designed to move large volumes over long distances with high efficiency and low energy consumption.

Industries such as mining, construction, power generation, and metallurgy rely heavily on conveyor belts. As industrial production scales, conveyor systems are becoming longer, heavier, and more complex, with some reaching several kilometers in length. The belt alone can represent up to 60 percent of the total system cost, making its performance and condition vital to operational success.

Failures in the belt can disrupt production, increase safety risks, and lead to significant financial losses. For this reason, continuous monitoring is not just beneficial; it is essential to maintaining system stability and productivity.

One faulty belt
can shut down the entire line.

Manual Inspections Are Slow and Error-Prone

Traditional conveyor monitoring relies on workers physically inspecting belts for wear or damage. These manual processes are time-consuming and often miss early signs of failure.

Undetected Damage Escalates Quickly

A small tear or thin spot may seem harmless, but under continuous operation, these faults grow rapidly. If not detected early, they escalate into major failures that require costly repairs and bring production to a standstill.

Belt Failures Shut Down Operations

Tears, blockages, and belt degradation don’t just interrupt production. They raise safety risks, increase maintenance costs, and reduce overall efficiency. Without real-time monitoring, companies are left reacting to problems instead of preventing them.

Our Solution

Beltision’s intelligent conveyor belt monitoring system harnesses real-time data and AI analytics to detect critical issues, such as tears, thickness reduction, and material anomalies, before they disrupt your operations. Our solution empowers industrial teams to maintain continuous production, prevent costly failures, and maximize equipment life.

Minimize Unplanned Downtime

Continuous, real-time monitoring detects warning signs early, allowing you to address issues before they cause unexpected downtimes.

Extended Equipment Life

Early identification of tears, thickness reduction, and irregularities helps you address issues at their source, maintaining optimal belt health and extending overall equipment life.

Lower Repair and Maintenance Costs

Operators can tailor the alerts based on their specific needs and preferences, receiving notifications about critical issues directly to their mobile devices. These alerts provide prompt information about potential disruptions or abnormalities in conveyor performance. With immediate awareness of such issues, operators can respond swiftly to prevent or mitigate disruptions before they escalate, ensuring uninterrupted operations and minimizing downtime.

Optimize System Performance

Automated analysis ensures your conveyor belts run efficiently, reducing energy waste and bottlenecks while boosting overall productivity.

One faulty belt can shut down the entire line.

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1.Mining

Conveyors are essential for transporting ore over long distances in continuous operations, both underground and above ground.

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2. Construction & Aggregates

Belt systems move heavy materials like gravel, sand, and stone from extraction sites to processing or transport zones.

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3.Power & Utilities

Fuel materials such as coal or biomass are conveyed continuously to maintain energy generation and boiler feed systems.

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4.Heavy Manufacturing

Assembly lines and raw material workflows rely on belts to keep production consistent and synchronized.

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5.Ports & Logistics

Bulk handling systems use belts for loading, unloading, and internal routing of goods across terminals and warehouses.

Contact us

Utilize our expert assistants to provide tailored maintenance solutions by sharing your inquiries and suggestions. They’ll help guide you toward a personalized approach to addressing your needs and concerns.