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Tru-Trac

Solutions

Solve the conveyor problem,
not just the component failure.

Belt mistracking, carryback, spillage, impact damage, idler wear and unplanned stoppages are rarely isolated problems. They are usually symptoms of a conveyor system that is not being controlled at the right point.

Tru-Trac solutions are built around the operating condition, the failure mode and the consequence of failure. We help identify the control point, specify the right product family, support the installation standard where required and route the issue into the correct next step.

Find the Right Solution PathRequest AssessmentExplore the Tru-Trac System

02 / Problem pathways

What problem are you trying to control?

Start with the failure mode. Tru-Trac will route the solution through the correct products, installation method, proof pathway and support model.

  1. 01

    Problem

    Belt mistracking

    What it means

    Belt drift, edge damage, structural contact, return-side instability or repeated manual adjustment.

    Cost if ignored

    Premature belt damage, spillage, safety exposure, emergency repair and production interruption.

    View Tracking Solutions
  2. 02

    Problem

    Carryback and spillage

    What it means

    Material returns on the belt, falls from the return side, contaminates idlers or creates clean-up exposure.

    Cost if ignored

    Higher maintenance hours, idler failure, pulley build-up, unsafe access and recurring clean-up cost.

    View Cleaning Solutions
  3. 03

    Problem

    Impact and transfer damage

    What it means

    Load-zone impact, belt sag, chute instability, material turbulence and transfer-point wear.

    Cost if ignored

    Belt cover damage, structural wear, spillage, unstable tracking and repeated transfer-point maintenance.

    View Load-Zone Solutions
  4. 04

    Problem

    Dust and sealing failure

    What it means

    Material escape, fugitive dust, skirt wear and poor containment at transfer points.

    Cost if ignored

    Housekeeping load, safety exposure, environmental pressure and material loss.

    View Sealing Solutions
  5. 05

    Problem

    Idler and roller failure

    What it means

    Premature idler wear, seized rollers, bearing issues, structural wear and repeat replacement.

    Cost if ignored

    Higher spare consumption, belt damage risk, unplanned downtime and return-side instability.

    View Idler and Frame Solutions
  6. 06

    Problem

    Monitoring and protection gaps

    What it means

    Delayed intervention, lack of measurement, late detection of belt damage or process risk.

    Cost if ignored

    Poor decision visibility, avoidable damage escalation and reactive maintenance.

    View Monitoring Solutions
  7. 07

    Problem

    Unplanned stoppages and repeat failures

    What it means

    Recurring stoppages, emergency call-outs, weak maintenance predictability and unstable availability.

    Cost if ignored

    Lost production, management distraction, premium spares, emergency labour and commercial risk.

    Explore Performance Partnership

03 / Solution families

Solution families built around conveyor behaviour.

Tru-Trac groups its solutions around how conveyors fail in the field: where material is loaded, where the belt begins to drift, where carryback develops, where impact occurs, where return-side instability compounds and where inspection data is needed to prevent repeat failure.

04 / The failure loop

The failure is not isolated. It compounds.

Misalignment, carryback, spillage, idler wear, belt damage and emergency maintenance often feed into one another. Tru-Trac's approach is to identify where the loop starts and control the conveyor as a system.

Stage count

7stages

Each failure compounds the next.

System type

Self-reinforcing

No single intervention breaks the cycle.

01
Belt misalignment
02
Carryback & spillage
03
Idler wear & failure
04
Belt damage
05
Unplanned stoppage
06
Emergency call-out
07
Deferred inspection

Reactive cycle

Failure compounds
the next failure

Live readout

Stage 01 / 07

Belt misalignment

Controlled outcome

−62%

Average reduction in unplanned stoppages once the loop is broken at source.

See the Full Failure Loop

05 / From component to programme

One engineering standard. Three ways to engage.

Some operations need a correctly specified component. Some need installation and commissioning support. Some need a full performance partnership.

  1. Mode 01

    Component Specification

    Teams that know the application and need the correct product family, technical data and specification support.

    Browse Components

  2. Mode 02

    Installation & Commissioning

    Projects where correct installation, baseline checks and sign-off matter as much as the product selected.

    See Commissioning Standard

  3. Mode 03

    Performance Partnership

    Operations where recurring conveyor instability requires inspection discipline, maintenance governance, field support and performance accountability.

    Request Partnership Assessment

06 / Solution detail

What each solution actually does.

  • 01 · Detail

    Tracking & Alignment Control

    When a belt does not run true, the visible damage is usually only the end result. Tru-Trac assesses where the mistracking begins, then specifies carry-side and return-side tracking control for the actual duty.

    Typical outcomes

    Reduced edge damage, fewer manual adjustments, improved return-side stability.

    View Tracking Solutions

  • 02 · Detail

    Cleaning & Carryback Control

    Carryback drives clean-up labour, idler contamination, pulley build-up, secondary mistracking and safety exposure. Tru-Trac cleaning solutions are specified around material, belt speed, pulley geometry, blade contact and maintenance access.

    Typical outcomes

    Reduced carryback, reduced idler contamination, lower clean-up exposure.

    View Cleaning Solutions

  • 03 · Detail

    Impact & Transfer Point Control

    The load zone is where many conveyor failures begin. Poor material loading, impact and belt sag create tracking instability, belt damage, spillage and transfer-point wear.

    Typical outcomes

    Improved belt support, reduced transfer-point damage, better containment.

    View Load-Zone Solutions

  • 04 · Detail

    Skirting, Sealing & Dust Control

    Spillage and dust are not only housekeeping problems. They create maintenance load, safety exposure, environmental pressure and unnecessary loss of material.

    Typical outcomes

    Better containment, lower clean-up burden, reduced dust and material escape.

    View Sealing Solutions

  • 05 · Detail

    Idlers, Rollers & Structural Support

    Recurring idler failure usually indicates a specification or installation problem rather than a product problem. Tru-Trac matches idler families to duty cycle, environment and structural reality.

    Typical outcomes

    Lower idler failure rate, better return-side stability, fewer belt-damage incidents.

    View Idler Solutions

  • 06 · Detail

    Monitoring, Measurement & Protection

    High-value operations need more than mechanical control. They need measurement and protection systems that help teams detect risk early and support planned intervention.

    Typical outcomes

    Improved visibility, better protection, stronger basis for planned intervention.

    View Monitoring Solutions

07 / Proof

Proof that the system approach works.

  • Case 01 · PGM mine, Rustenburg

    Problem

    Multiple previously installed tracking products failed to resolve the issue, contributing to a two-day production halt. Tru-Trac assessed the application, replaced the failed units with two correctly specified trackers and restored production.

    Outcome

    Belt centralised within 20 seconds and remained true under full load.

    Read the case

  • Case 02 · Coal stacker reclaimer, Germany

    Problem

    A 2,300mm belt operating at 9.6 m/s had defeated previous tracker solutions, with products lasting less than one week. Tru-Trac developed an Extra Heavy-Duty tracker for the application.

    Outcome

    Tracker still performing after more than 12 months and the customer standardised on the solution.

    Read the case

  • Case 03 · Copper mine, Zambia

    Problem

    A high-tonnage conveyor was contacting structural steel, damaging the belt edge and creating fire risk. Tru-Trac installed Apex tracking technology to control the belt at the origin and return side.

    Outcome

    Immediate centralisation on start-up, structural contact stopped and the site standardised on Tru-Trac tracking solutions.

    Read the case

08 / Related resources

Deeper reading, public + gated.

Start with the conveyor problem in front of you.

Choose the failure mode, review the relevant solution pathway, or submit the conveyor details for technical assessment.

Find the Right Solution PathRequest AssessmentExplore the Tru-Trac System