Cases
Real conveyor problems.
Measured outcomes.
Tru-Trac case studies focus on what changed: belt stability, unplanned stoppages, belt life, carryback, spillage, safety exposure, maintenance load and standardisation across the operation. Where customer names are not disclosed, we identify the commodity, region, conveyor condition, failure mode, intervention and outcome. The proof is in the operating result, not the logo.
Customer names shown only where permission has been confirmed.
Evidence file
6 verified cases · 4 commodities · 2 regions
- Case 01PGM · Rustenburg, South Africa20sto centralise
- Case 02Coal · Germany12+ movs <1 week prior
- Case 03Copper · Zambia0structural contact events
02 / Featured case
Production halt reversed after multiple failed tracking interventions.
PGM mining · Rustenburg, South Africa
A PGM operation in Rustenburg experienced a two-day production stoppage after multiple previously installed tracking products failed to resolve the issue.
Before · failure condition
Multiple previously installed tracking products failed to hold the belt true. The belt repeatedly drifted off centre under variable load.
Centralised in
20s
Under full load
After · stabilised condition
Tru-Trac assessed the application, replaced the failed units with two correctly specified belt trackers, and restored production. Belt remained true under full load from the first shift.
Customer anonymised. Outcome based on verified Tru-Trac case material.
Read the Case03 / Browse the proof
Filter by commodity, region, failure mode, or product family.
Showing all 6 verified cases below.
Commodity
Region
Failure mode
Product family
- Case 01PGM · Rustenburg, South Africa20sto centralise
The belt centralised within 20 seconds and remained true under full load from the first shift. The site has since adopted the same tracker specification across similar belts.
- Mistracking
- Standardisation
- Belt Trackers
- Case 02Coal · Germany12+ movs <1 week prior
The EXHD tracker has performed for over 12 months with no replacement. The customer adopted the Tru-Trac specification standard for similar applications across the operation.
- Mistracking
- Standardisation
- Belt Trackers
- Case 03Copper · Zambia0structural contact events
Belt centralised immediately on start-up. Structural contact stopped. The site adopted the Tru-Trac specification across similar applications.
- Mistracking
- Belt Damage
- Belt Trackers
- Case 04Platinum · South Africa~4 yrsbelt life
Spillage and edge damage were both eliminated. The belt operated for almost four years before scheduled replacement — well above prior service life.
- Mistracking
- Spillage
- Belt Trackers
- Case 05Coal · Coal Mining Operation0spillage events
Spillage was completely eliminated. The sealing system was restored to its intended function.
- Mistracking
- Spillage
- Belt Trackers
- Case 06Copper · Copper Processing+monthly output
Belt damage was eliminated. Monthly production output improved. The site ordered additional units for preventative maintenance on similar belts.
- Mistracking
- Belt Damage
- Belt Trackers
Get the conveyor problem checklist used in our assessments. Identifies failure modes by observable symptom — same checklist our engineers use on site.
Download the checklist04 / Pattern of outcomes
Different conveyors. Same pattern of control.
The problem changes by site: mistracking, carryback, spillage, belt-edge damage, idler contamination, fire risk, or emergency stoppages. The pattern is consistent. When the conveyor is assessed correctly and the right control point is specified, downstream cost and risk begin to fall.
- 01
Controlled
Tracking stability under load
Observed
Belt centralised within seconds; held under variable load.
Context
PGM, Platinum, Copper
- 02
Controlled
Extreme-duty performance
Observed
Tracker held 12+ months where prior products failed in days.
Context
Coal stacker reclaimer, Germany
- 03
Controlled
Site-wide standardisation
Observed
After one belt succeeded, operation adopted the spec across similar belts.
Context
PGM, Coal, Copper, Platinum
- 04
Controlled
Sampler / sealing zone stability
Observed
Belt stability at sampler restored sealing system function.
Context
Coal overland
- 05
Controlled
Return-side control
Observed
Dual Return Trackers held high-tension wide belts true on return run.
Context
Copper tripper conveyor
05 / Methodology
How Tru-Trac builds a case study.
A Tru-Trac case study is built from field evidence. Each case identifies the operating condition, the failure mode, the intervention, and the measured outcome. Where customer names are not shown, the case remains specific through commodity, region, conveyor condition, product family, and result.
- 01
Operating condition
Belt width, speed, load, material, environment, duty cycle.
- 02
Failure mode
Mistracking, carryback, spillage, idler failure, belt damage, safety exposure.
- 03
Intervention
Correctly specified components, installed and commissioned to a documented standard.
- 04
Measured outcome
Operational result recorded against a baseline; verified before publication.
Request the technical evidence pack for a similar application. We assemble matched-application evidence (belt width, speed, commodity, failure mode) on request.
Request the evidence pack06 / Customer statements
Verified outcomes, in customer voices.
Approved customer statements that speak to how Tru-Trac validates outcomes — proof-of-concept methodology, accuracy under audit, and ongoing technical support.
Belt Scales
Accurate production, sales and stock measurement is critical to managing the operation properly. The Tru-Trac belt scale helped us improve confidence in the numbers and reduce the time and cost associated with stock reconciliation.
Lloyd · Works Manager · AfriSam Coedmore Quarry
Belt-scale accuracy supports better production control, stock management and operational decision-making.
Belt Scales
Tru-Trac proposed a proof-of-concept belt scale installation for one month. After reviewing the results, we were impressed by the accuracy and by the service support. They trained us on in-house calibration, and a technician continues to visit site monthly.
Dustin · Maintenance Superintendent · AfriSam Coedmore Quarry
Proof-of-concept installation demonstrated accuracy before full commitment.
07 / Gated proof resources
Deeper proof, on request.
Detailed PDF case summaries, the conveyor problem checklist our engineers use on site, and application-matched technical evidence packs. Sent on request after a brief contact form.
- 01Gated
Detailed case summary
Full PDF of the Rustenburg PGM case — operating condition, failure mode timeline, intervention spec, and measured outcome.
Download the case summary - 02Gated
Conveyor problem checklist
The same field checklist Tru-Trac engineers use during a site assessment. Identifies failure modes by symptom.
Get the checklist - 03Gated
Technical evidence pack
Application-matched evidence: similar belt width, speed, commodity, and failure mode. Built per request.
Request the evidence pack
Start with the conveyor that keeps coming back.
If the same belt keeps mistracking, spilling, damaging itself, contaminating idlers, or forcing unplanned intervention, the issue is rarely isolated. Tru-Trac can assess the conveyor, identify the failure mode, and recommend the correct control point.