Having initially made its name as a world leader in conveyor belt alignment solutions, Tru-Trac has expanded over almost 30 years to offer a comprehensive suite of products and services designed to minimise conveyor-related hazards and create a safer, more productive work environment.
The company originally patented its first innovative Tru-Trac Tracking Systems in 1996 – which continuously and autonomously guides the belt to the centre position. It has since expanded its product offering to become a world leading manufacturer and supplier of conveyor belt solutions.
“When we entered this market in the mid-1990s, it was still considered acceptable for a belt smith to stand next to a conveyor belt and physically adjust the idler frames to try and align the belt,” says Jonathan Rogoff, CEO of Tru-Trac Rollers. “This was done, of course, while the belt was moving – a very hazardous practice, which thankfully is no longer allowed.”
Today, workers are not permitted near a moving conveyor belt. What has made this possible is the success of belt alignment technologies that can operate reliably and without human intervention. Conveyor belt misalignment creates other safety hazards such as material spillage, which can lead to slips, trips and falls for workers. Misalignment causes uneven stress on the belt, leading to faster wear and potential failure; this can create a dangerous situation if it occurs during operation.
This maintenance-free capability of Tru-Trac Tracking Systems ensures there is minimal physical contact required from mine employees, further supporting the policy of maintaining a safe distance by all workers. The company’s trackers employ a unique action that does not damage the belt and reacts immediately if the conveyor belt begins to drift off-centre. Being simple to install, they have a vibration-free rolling action and can be installed above or below the belt on the return side.
On the strength of its tracking systems, Tru-Trac grew rapidly over the years to encompass a comprehensive offering of conveyor belt solutions – from conveyor skirting and impact beds to standard idlers and frames. The company also developed a range of high-performance belt scrapers, including primary and secondary scrapers as well as angle and V-ploughs, which contribute to a healthier, more productive workplace and fewer maintenance headaches.
Beyond conveyor misalignment, an often-overlooked safety hazard lies in conveyor belt carryback. This is material that adheres to a conveyor belt after it has passed the discharge point. The build-up of material presents several dangers, including fire hazards when flammable material – that may ignite due to friction or external heat – accumulates. Carryback can also create slippery surfaces and generate harmful dust.
“If a mine’s belt scrapers are not performing well enough to clean the belt, then it will experience carryback across the entire length of the conveyor belt,” he says.
Belt scrapers play a vital role in preventing carryback, and Tru-Trac designs and manufactures a wide range of high-performance belt scrapers with a superior tensioning system that maintains tension throughout the life of the blade. Belt support is also important in minimising the health hazard of excessive dust and spillage at the load area of conveyor belts, says Rogoff.
“It is critical to be able to support the belt well through a combination of heavy-duty impact beds and a good skirting rubber,” he explains. “If the belt is not supported, it will drop down, and material will spill.”
One of the unique features of the Tru-Trac adjustable impact bed is the ability to achieve fine adjustments on the troughing angle to suit the user’s application. This ensures an effective seal between the belt and the skirting rubber.
“Most of the products available on the market are set to 35% or 45%, but this does not always match what the mine needs,” he says. “If the requirement is actually 34%, our impact bed can be adjusted to exactly the right position – as that 1% difference will enhance the sealing and prevent any spillage.”
The choice of skirting rubber is also an important consideration, Rogoff continues. Tru-Trac’s comprehensive range of skirting rubber allows careful selection of the most appropriate type to match the application.
“When it comes to skirting rubber, it is not a case of one-size-fits-all,” he emphasises. “Not many providers offer a variety, but we will go to site and assess which type of rubber is best for the customer. This allows a choice between a continuous skirting, for instance, and a block-type or segmented skirting – or even a skirting with a polyurethane edge to provide good wear resistance and seal.”
Shaun Blumberg, COO of Tru-Trac, reiterates that conveyor belts represent a serious safety hazard in mines, both underground and on surface operations. He explains that the cornerstone of the company’s safety solutions is to prioritise belt inspections and proactive maintenance.
“Regular inspections and maintenance are essential to mitigating risk and optimising performance,” says Blumberg. “Our trained conveyor specialists conduct systematic conveyor inspections as part of our comprehensive full-service offering.”
This is done with a dual focus on safety and performance, he says, where customers receive detailed digital reports on the performance and condition of each component of their conveyor system. This work is based on a preventative maintenance approach, which avoids downtime by identifying any potential sources of failure before it can occur. Maintenance services are offered on a contract basis, he explains, and extend to large operations having dedicated conveyor maintenance teams on site on a full-time basis.
“Having trained maintenance teams responsible for conveyors not only ensures that your operations continue to run reliably and effectively, but that they support the mining industry’s goal of Zero Harm,” he says.
This includes the identification of hazards such a nip or pinch points, which can be mitigated with the use of the Tru-Trac Nip Guard and Safe Guard.
