Conveyor belt misalignment and roller slippage are among the most persistent and costly problems in mining and bulk materials handling operations, says conveyor belt solutions manufacturer and supplier Tru-Trac.

“When you calculate the production losses, unplanned maintenance and shortened belt life caused by misalignment the savings from properly aligned systems are substantial. Our Apex Series and Grip-Trac range are designed to pay for themselves many times over during the life of the conveyor,” says Tru-Trac national sales manager Guy Fitt.

Belt mistracking can stop production, force emergency shutdowns and drive up operating costs through increased spillage, damage to structure and premature belt wear. The company’s Apex series trackers are designed to minimise these risks by providing faster correction and more stable belt alignment, even under fluctuating loads and speeds.

A key feature is the use of adjustable wing rolls on the trough units, giving operators greater control in stabilising the belt path. This innovation aims to reduce the likelihood of spillage and uneven wear while extending the working life of the belt.

Slippage between belt and rollers also contributes to lost productivity and roller wear. Traditional lagging solutions, often relying on standard rubber or polyurethane compounds, tend to wear quickly in demanding mining conditions, asserts Tru-Trac. Its Grip-Trac lagging solution aims to address this problem through a reinforced rubber compound with greater wear resistance, combined with a tread pattern specifically designed for mining applications.

The pattern is designed to improve traction, disperses water and fines and reduces heat build-up and uneven wear. It also acts as a built-in wear indicator, giving maintenance teams a signal for timely intervention. “This extends service life and reduces the risk of unexpected failures. It allows mines to plan maintenance, rather than react to breakdowns,” notes Tru-Trac technical manager Gerhard Strydom.

According to Tru-Trac manufacturing manager Franco Cloete the commercial value of these products lies as much in the way they are built as in their design. “Every Apex Tracker and roller with Grip-Trac lagging is manufactured to exacting standards in our South African facility,” he says.

Tru-Trac underlines that its belt tracking and lagging technologies have been proven across multiple continents from chrome operations in South Africa to coal mines in South America and iron-ore operations in Australia.