Conveyor Assessment · Site Audit · Engineering Diagnosis
Find out what is actually wrong with the conveyor.
A Tru-Trac conveyor assessment is a structured engineering review of the belt, loading conditions, tracking behaviour, carryback, transfer points, idlers, pulleys, maintenance history and recurring failure pattern. The output is not a generic sales visit. It is a practical technical recommendation.
02 / When to request
When the same conveyor problem keeps coming back, the issue is usually not the last component that failed.
A conveyor assessment is most valuable when the site is spending time, money and maintenance effort on recurring symptoms without a clear view of the underlying cause.
Trigger 01
Belt mistracking
The belt drifts, wanders or contacts structure even after repeated adjustment.
Trigger 02
Carryback and spillage
Material returns on the belt, builds up on idlers, falls onto walkways or drives recurring clean-up.
Trigger 03
Premature belt damage
Belt edges are fraying, the belt is wearing unevenly, or splice and repair work is becoming routine.
Trigger 04
Idler and pulley contamination
Return idlers, pulleys and structure are being contaminated by carryback or spillage.
Trigger 05
Load and transfer instability
Material is loading off-centre, impact zones are unstable, or transfer points are causing downstream problems.
Trigger 06
Unplanned stoppages
The conveyor stops unexpectedly and the same failure pattern returns after emergency repair.
Trigger 07
Specification uncertainty
A project, tender or replacement decision requires technical input before equipment is selected.
Trigger 08
Distributor technical support
A regional partner needs manufacturer input before recommending a product or support pathway to an end customer.
03 / What we assess
We assess the conveyor in its operating environment, not just on a drawing.
The assessment follows the belt through the approved five-zone Tru-Trac System model. Scope can begin with one problem belt, a remote review from photos and drawings, or a broader site or fleet audit.
- 01
Zone
Load & Transfer Zone
Inspection focus
Material loading position, impact condition, belt support, chute influence, transfer-point control, skirting condition and where instability enters the system.
- 02
Zone
Carry-Side Tracking
Inspection focus
Belt lateral movement, tracker suitability, tracker position, structural contact, belt-edge condition and whether correction occurs at the right point.
- 03
Zone
Discharge & Cleaning
Inspection focus
Primary and secondary cleaner condition, blade contact, cleaner geometry, carryback thickness, pulley build-up and material release after discharge.
- 04
Zone
Return-Side Stability
Inspection focus
Return tracking, carryback contamination, seized or worn idlers, pulley contact, belt lift, return-side mistracking and tail pulley protection.
- 05
Zone
Monitoring & Protection Layer
Inspection focus
Belt damage indicators, metal contamination risk, inspection discipline, downtime history, belt scale/monitoring needs and intervention triggers.
04 / Deliverables
A technical recommendation the site can act on.
Practical for maintenance teams, credible for engineers, clear for procurement and management. The aim is to identify the problem, rank the priorities and define the next engineering action — not to produce a long report that sits in a folder.
- 01Conveyor condition summary.
- 02Failure-mode diagnosis, with origin and downstream consequences identified.
- 03Photographic evidence and operating-condition notes.
- 04Assessment of existing products and whether they are correctly specified.
- 05Recommended product families and specification direction.
- 06Installation and commissioning considerations.
- 07Priority ranking: urgent, high, medium or monitor.
- 08Maintenance and inspection recommendations.
- 09Optional cost-of-failure reconstruction where site data is available.
- 10Commercial proposal or pilot scope, where requested.
05 / Process
Start with the conveyor. Decide the next step after the diagnosis.
01
Initial intake
The customer submits a short description of the problem, site location, commodity, belt details, photos, drawings and urgency.
02
Technical triage
Tru-Trac reviews the information and routes the query to the correct engineering, technical sales or regional support team.
03
Remote review or site assessment
The assessment may begin remotely from supplied material or continue on site, ideally under loaded and unloaded conditions.
04
Diagnosis
Findings are reviewed against the failure pattern, installed products, operating envelope and maintenance history.
05
Recommendation
Tru-Trac provides a technical recommendation, priority ranking and specification direction.
06
Next step
The site can proceed with component supply, installation support, pilot belt scope, distributor-supported action or broader performance partnership discussion.
06 / Assessment types
Six routes, one engineering pathway.
Pick the one closest to your situation. The form below pre-selects the matching assessment type.
07 / Proof
Assessment changes the outcome because it changes the question.
When the real failure mode is understood, the right intervention often becomes simpler, faster and more defensible.
Case 01 · PGM mining · Rustenburg
Finding
Multiple previously installed tracking products failed to resolve the issue, contributing to a two-day production halt. Tru-Trac assessed the belt and replaced the failed units with two correctly specified trackers.
Outcome
Belt centralised within 20 seconds and remained true under full load.
Case 02 · Coal sector · Germany
Finding
A 2,300 mm belt running at 9.6 m/s had defeated previous tracker solutions, with products lasting less than one week. Tru-Trac assessed the duty and supplied an Extra Heavy-Duty tracker.
Outcome
Tracker still performing after more than 12 months.
Case 03 · Copper mining · Zambia
Finding
A high-tonnage conveyor was contacting structural steel, damaging the belt edge and creating fire risk. Tru-Trac inspected the conveyor and specified trough-side and return-side tracking control.
Outcome
Immediate centralisation on start-up and site-wide standardisation on Tru-Trac tracking solutions.
08 / Request the assessment
Share what you know. The more operating detail, the faster we route it.
If you do not have drawings or full belt data, submit anyway. Assessment can start from photos, drawings, maintenance notes or a short video.
09 / Common questions
Common questions, answered.
Practical objections answered before you submit. The form takes free-text context too if your question isn't here.
No. The purpose is to understand the operating condition, identify the failure mode and recommend the appropriate technical path. A proposal may follow, but the assessment starts with the conveyor, not the product list.
Start with the conveyor that gives you the most trouble.
Tell us where the failure repeats. Tru-Trac will help determine whether the problem starts with tracking, loading, cleaning, impact, maintenance discipline or system behaviour.