An iron ore mine in Mauritania was facing considerable safety risk and maintenance costs due to misalignment of its conveyors, until Tru-Trac implemented the solution.

According to Ian King, Sales Manager Africa at Tru-Trac, the customer was visited by Tru-Trac’s representative in West Africa, and an on-site assessment was conducted to analyse the challenges being experienced.

“We recognise that no two conveyors are the same, so it is important to start with a thorough physical inspection,” says King. “This provides the basis for our customised solutions, and allows us to apply the right expertise and equipment.”

This led to the involvement of Tru-Trac’s Technical Sales Engineer, Muller Joubert, who provided further technical assistance in developing the optimal solution. Joubert then spent time at the site, ensuring speedy installation.

“Our on-site survey revealed that several of the mine’s conveyor belts were running into the sides of the structure,” he explains. “This prolonged misalignment had caused significant damage to the conveyor sidewalls. A more serious risk was that this grinding against the structural framework posed a serious safety risk – as the potential build-up of heat in the conveyor belt could escalate into a fire hazard.”

Tru-Trac reported on its findings, highlighting the urgency of the situation to prevent further damage and to allay the safety risk. The company’s recommendation was to install the trusted Tru-Trac V-Return self-alignment trackers, he explains.

“These innovative solutions are designed to correct belt misalignment automatically, ensuring that the conveyor stays centred even under challenging conditions,” he says. “Even though the conveyor belts had been slightly damaged by the contact with the structures, our solution ensured that the belt could continue operating safely for some time – saving on considerable replacement costs.”

The Tru-Trac trackers’ effect was immediate, he says, aligning the belts centrally within the conveyor structures and preventing any further damage to the belt’s sidewall. As importantly, Tru-Trac’s work on the conveyor system was able to stop spillage from the belt and avoid downtime for maintenance – with both these factors contributing to the mine’s production capability. A total of eight Tru-Trac V-Return trackers were installed across three of the mine’s conveyors, located about 40 metres apart.

As it was no longer necessary for employees to work next to the conveyor to clean up the spilled material, the operation became safer and more efficient. It was also important to ensure that the trackers could operate sustainably in the harsh desert-like environment with extreme temperatures and frequent dust storms.

“Our trackers are built with sealed mechanisms, ensuring that no dust or debris can compromise their performance,” says Joubert. “This design ensures long-lasting functionality, even in the severe climates and punishing operating conditions so often found on mining sites across Africa and elsewhere.”

He also highlights that the design facilitates quick and hassle-free maintenance to reduce downtime, including a simple roller replacement process and adjustable mounting brackets.

“Our self-alignment frames are designed for maximum efficiency,” he explains. “The maintenance technician simply loosens two screws on the side of the frame, then releases tension. They drop the frame and remove one more bolt before swopping out the idler and installing a new one.”

This only takes about 20 minutes, which is a dramatic improvement on traditional maintenance times. The result is less standing time and higher productivity, he points out. 

“To customise our solutions, we manufacture our trackers to suit the specific belt width, belt speed and tonnage per hour carried by the conveyor,” says Joubert. “In this case, our trackers were designed for the specific conveyor running between 2,7 metres and 3,2 metres per second.”

He concludes that Tru-Trac’s confidence in its trackers is based on global experience, where they have seen the units performing well after more than seven years.

“With proper maintenance and regular support, we expect the same outstanding performance from the units we have installed at this mine in Mauritania,” he says.