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. Tru-Trac looks at the conveyor as a system, then identifies where the failure starts, where it compounds and what needs to be controlled first.
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 where required.
- 01
Load & Transfer Zone
Material loading position, impact condition, belt support, chute influence, transfer-point control, skirting condition and where instability enters the system.
- 02
Carry-Side Tracking
Belt lateral movement, tracker suitability, tracker position, structural contact, belt-edge condition and whether correction occurs at the right point.
- 03
Discharge & Cleaning
Primary and secondary cleaner condition, blade contact, cleaner geometry, carryback thickness, pulley build-up and material release after discharge.
- 04
Return-Side Stability
Return tracking, carryback contamination, seized or worn idlers, pulley contact, belt lift, return-side mistracking and tail pulley protection.
- 05
Monitoring & Protection Layer
Belt damage indicators, metal contamination risk, inspection discipline, downtime history, belt scale/monitoring needs and intervention triggers.
Additional assessment inputs
01
Installed product specification
Against belt width, speed, tension, load, material, environment and duty cycle.
02
Maintenance behaviour
Adjustment frequency, emergency response pattern, inspection discipline, spare consumption and downtime records.
03
Commercial consequence
Lost production, clean-up labour, premature replacement, emergency call-outs, safety exposure and avoidable maintenance cost.
04 / What you receive
A technical recommendation the site can act on.
The assessment output must be practical enough for maintenance teams, credible enough for engineers and clear enough for procurement and management. The aim is not to produce a long report that sits in a folder. The aim is to identify the problem, rank the priorities and define the next engineering action.
- 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 / How it works
Start with the conveyor. Decide the next step after the diagnosis.
The process is sequential. Each step narrows the question, so the engineering recommendation at the end is matched to the conveyor — not to a catalogue.
06 / Assessment types
Pick the assessment type that matches the question in front of you.
Different visitors arrive with different questions. The form below pre-selects the assessment type from whichever card you pick here.
Problem Belt Assessment
A recurring issue on a specific conveyor: mistracking, carryback, spillage, belt damage, idler contamination or repeated stoppages.
Request Problem Belt Assessment
Remote Technical Review
Early-stage review based on photos, videos, drawings and maintenance notes where a site visit is not yet practical.
Submit Photos or Drawings
Project Specification Review
EPCMs, project engineers and plant teams specifying equipment for a new or modified conveyor.
Submit Project Specification
Fleet or Site Audit
Operations with repeated conveyor instability across multiple belts or inconsistent specifications across a plant.
Request Site Audit
Performance Partnership Assessment
Operations considering embedded support, maintenance governance or KPI-linked performance model.
Discuss Performance Partnership
Distributor Support Request
Regional partners seeking manufacturer support on a customer conveyor problem or project specification.
Request Manufacturer Support
07 / Proof
Assessment changes the outcome because it changes the question.
The strongest Tru-Trac engagements start with diagnosis. When the real failure mode is understood, the right intervention often becomes simpler, faster and more defensible.
PGM mining · Rustenburg
20s
to centralise
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.
Belt centralised within 20 seconds and remained true under full load.
Read case
Coal sector · Germany
12+ mo
in service
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.
Tracker still performing after more than 12 months.
Read case
Copper mining · Zambia
0
structural contact
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.
Immediate centralisation on start-up and site-wide standardisation on Tru-Trac tracking solutions.
Read case
08 / Submit the request
Request a conveyor assessment.
Share what you know. The more operating detail you provide, the faster Tru-Trac can route the request to the correct technical team. If you do not have drawings or full belt data, submit the request anyway. Assessment can start from photos, drawings, maintenance notes or a short video.
🔒 Technical submissions are treated as confidential and used only to assess and route the conveyor requirement.
09 / Frequently asked
Practical questions, answered directly.
Operations and engineering teams ask these before submitting. If your question is not here, write it into the problem description on the form below.
01Is a conveyor assessment the same as a sales visit?
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.02Do you need to come to site?
Not always. A remote review can start from photos, videos, drawings and maintenance history. Some issues still require a site visit before a final recommendation.03How long does an assessment take?
A focused problem-belt assessment can often be completed in one site visit. Larger fleet or site audits may take several days depending on access, number of conveyors and operating conditions.04Do you need the conveyor to be running?
Ideally yes. Loaded and unloaded observations provide the best insight. Where this is not possible, supplied media and maintenance history can still provide a useful starting point.05Can distributors request manufacturer support?
Yes. Regional partners can submit customer conveyor information for Tru-Trac technical review, specification input or escalation support.06Can the assessment lead to a pilot?
Yes. For high-value or recurring problems, Tru-Trac may recommend a one-belt pilot with defined scope, installation standard, monitoring period and reporting output.
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.