Optimising conveyor efficiency with tailored belt tracking solutions

Effective conveyor belt tracking is essential for maintaining operational efficiency and preventing issues on conveyor belt systems and belt trackers, although seemingly small components, play an important role in maintaining the alignment and smooth operation of conveyor belts.

According to Gerhard Strydom, Technical Product Manager at Tru-Trac, a leading authority in conveyor technology, a one-size-fits-all approach does not apply to belt tracking solutions. Proper specification and installation are critical to achieving the expected performance and longevity.

Strydom explains that key considerations in specifying belt trackers include belt speed, width, tension and tonnage per hour on the loading side. He emphasises the importance of gathering accurate application data to ensure the optimal solution is installed.

“Environmental factors such as dust, moisture and wind as well as the type of belt material - whether it is a steel core or solid woven belt - further influence the choice,” he explains. “Additionally, any specific challenges that the customer has experienced with the conveyor system need to be prioritised in the solution.”

Tru-Trac’s approach to belt tracking involves comprehensive assessment, preferably on-site, starting from the tail section of the conveyor. This method allows the company’s in-house specialists or trained distribution partners to gather operational data and understand historical challenges directly from belt attendants. "We prefer to base our assessment on an on-site walking inspection of the conveyor," Strydom says. This meticulous approach ensures that the trackers are tailored to the specific conditions and requirements of each conveyor system.

Tru-Trac offers a wide range of belt trackers, from entry-level units for the troughing or return side of conveyors to heavy duty applications capable of handling belt speeds up to 10 metres per second. The success of their design and technology has been proven across various industrial applications.

For instance, a South African platinum operation facing significant spillage and belt edge damage due to severe misalignment benefited immensely from Tru-Trac’s expertise. The installation of a Tru-Trac taper trough tracker after the loading zone and a dual return tracker before the tail pulley resolved the alignment issues, allowing the belt to operate for almost four years before requiring replacement.

A recent project at a prominent copper mine in Zambia demonstrated how changing conditions can affect the suitability and lifespan of a specified belt tracker. Ian King, Africa Sales Manager at Tru-Trac, recounts the challenges faced when the conveyor system experienced severe mistracking issues in the loading zone after production levels were increased without notification.

The high tonnage belt began to make contact with the structure, causing significant edge fraying and tearing, which reduced the usable width of the belt and compromised its overall performance. The existing alignment system was not robust enough to manage the severity of the mistracking, leading to downtime for belt and structural repairs, increased operational costs and a risk of fire.

To address these challenges, Tru-Trac local technicians conducted a thorough inspection of the conveyor system and installed the Tru-Trac Apex Tracking System. This solution included the installation of both trough side and return side trackers, strategically positioned to maintain belt alignment and prevent edge damage.

The trough side apex trough tracker was installed just after the loading zone, while the return side dual return tracker was placed near the tail pulley. These trackers engaged immediately on start-up, steering the belt to the centre position and continuously ensuring alignment thereafter. King says that the customer was extremely pleased with the performance of Tru-Trac's equipment, and that the aligned and protected belt not only enhanced safety but also improved our operational efficiency. The mine has now standardised on Tru-Trac belt misalignment solutions for other sections of the mine.

While Tru-Trac’s belt trackers are known for their robust design and even come with a lifetime warranty on some components, other aspects of the conveyor must be monitored carefully for optimal performance. Strydom highlights the importance of conveyor scrapers, which, if not fully functional, can impact the performance of the tracker.

"If the belt scraper is not working well, this can allow material to be carried back on the return side of the conveyor belt," he says. "This material builds up and can compromise the performance and functioning of a tracker."

As the costliest element of the conveyor system, the belt itself can be severely damaged by misalignment, often starting with wear on the edges. This leads to ply separation, allowing moisture to penetrate the belt carcass and degrade its integrity, usually resulting in premature failure. The acceptance of high performance belt trackers as a standard feature on a conveyor system has grown over the years, King notes. These units are often installed at the outset of a project rather than only after belt misalignment has been identified as a recurring issue. This proactive practice recognises the costly impact of conveyor system downtime, which can potentially bring all or part of an operation to a standstill.

“The adoption of advanced belt tracking solutions reflects the industry's recognition of their role in mitigating downtime and enhancing overall conveyor performance. We believe that Tru-Trac’s tailored approach, comprehensive assessments and high quality products ensure that our belt tracking solutions align with operational demands and environmental conditions, sustaining efficiency and productivity in diverse industrial applications,” King says.

“As conveyor systems continue to evolve, Tru-Trac will remain at the forefront, delivering reliable solutions that uphold the integrity and functionality of these essential systems,” he concludes.