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31 Aug 2026
BELT RIP PREVENTION
Flexco Elevate® Belt Rip Prevention System Helps Mining Operations Protect Conveyor Assets and Optimize Performance
As the mining industry faces a growing array of challenges, from volatile markets and intensifying competition, to decarbonization and regulatory compliance, Flexco is supporting the industry with a first-of-its-kind platform to digitize conveyors in a cost-effective manner through an OPEX model or a CAPEX model.
The Flexco Elevate® Belt Rip Prevention System utilizes an AI approach to produce technology that reduces sensor costs and makes digitization possible across the entire belt conveying process. Flexco Elevate® helps to protect investment, maximize the efficiency of conveyor lines, and prevent workflow interruptions.
Modern mining operations produce vast amounts of data every day. Much of this information is either unused or poorly leveraged to provide insights to mine operators. With the right tools, this data has the potential to reduce unplanned downtime and enable predictive analytics solutions.
Flexco uses data from the conveyor line for its AI-based predictive model to detect the most critical failure for a conveyor belt, the rip event. As mining operators face a future of dwindling resources and the challenges presented by deeper mines, rising energy costs, infrastructure shortages, and skill gaps, there has never been more pressure to improve efficiency and cut costs.
A predictive maintenance approach can offer significant savings. According to Deloitte analysis, predictive maintenance can reduce maintenance planning time by 20–50% and overall costs by 5–10%. Flexco Elevate® helps customers prevent unplanned shutdowns and optimize conveyor lines through detailed conveyor data analysis. Flexco remains committed to the development of solutions that limit unplanned conveyor shutdowns, increase energy efficiency, and reduce operating costs.
The Flexco Elevate® Belt Rip Prevention System is an intelligent platform solution designed to protect and optimize conveyor systems. Featuring a wide range of innovative functions, it detects and prevents damage early, reduces downtime, and maximizes operational efficiency.
Flexco Elevate® analyzes data from the conveyor with an AI-based predictive model to deliver the following functions:
- Rip Detection & Rip Prevention
- Anomaly Detection
- Motor Monitoring
- Energy Efficiency Analyzation
- Electrical Network Monitoring
- Mass Flow Calculation
- Gearbox & Bearing Monitoring
- Roller Monitoring
- iScale Function
The platform integrates a wide range of sensor data, enabling advanced analytics and proactive preventive maintenance strategies.
Beyond the initial purchase price, factors such as operating expenses, maintenance, and wear parts all play a role in determining a system’s total cost of ownership. Flexco Elevate® Belt Rip Prevention offers an advantage over standalone systems that rely on expensive hardware and per-unit subscription fees, particularly when it comes to cloud-based applications. Over a five-year period, Flexco Elevate® costs only 20% of competitor solutions. Due to wear components and subscription models, that gap continues to grow.
Flexco Elevate® also keeps sensitive data completely offline. Unlike solutions that send data to the cloud, Flexco Elevate® provides complete data sovereignty and helps protect against data leaking and hacker attacks.
Advanced Monitoring Functions
Drive Monitoring
Flexco Elevate® includes advanced motor monitoring that continuously tracks key electrical parameters. This approach detects early signs of wear and potential issues, enabling timely maintenance interventions that reduce downtime and help prevent costly failures while supporting motor performance and facility productivity.
Energy Efficiency
Through frequent conveyor monitoring measures, Flexco Elevate® helps optimize energy consumption, reduce operational costs, and lower CO₂ emissions.
Mass Flow Calculation & iScale
Based on electrical analysis, Flexco Elevate® provides mass flow calculation without wear components. Its self-calibration machine learning feature continuously adjusts to deliver accurate measurements, even in challenging environments, supporting process efficiency, cost savings, and operational excellence.
Electrical Network Analyzation
Flexco Elevate® continuously monitors power supply conditions and provides insights into harmonic distortions, voltage fluctuations, and other anomalies. This enables operators to identify inefficiencies, implement maintenance strategies, optimize energy consumption, and help protect critical assets from the risks associated with electrical network failures.
Gearbox & Bearing Monitoring
Advanced vibration analysis continuously monitors gearboxes and rolling bearings, detecting early signs of wear and imbalance before they develop into failures. By analyzing vibration patterns and identifying anomalies in real time, the system supports proactive maintenance, reduces downtime, extends equipment life, and enhances operational safety and efficiency.
The solution incorporates innovative 3-axis MEMS technology that delivers measurements in axial, vertical, and horizontal directions from a single measuring position. An ultra-durable stainless steel housing, built-in self-tests, M12 connector, and status LED support maintenance-free operation.
Using data analytics for gearbox monitoring, imbalance and bearing analyses enables continuous monitoring of fatigue, friction, shocks, and surface temperatures. With IO-Link integration into Flexco Elevate® and compliance with the ISO 20816-3 standard, limits can be adjusted to suit machine type and power rating.
Roller Monitoring
Flexco Elevate® enables the early detection of wear or imbalance and identifies the exact location of damage on carrying rollers. This targeted maintenance approach helps prevent minor issues from escalating into costly breakdowns or further damage.
The monitoring system also reduces maintenance efforts and downtime while eliminating the risks associated with inspections around moving machinery during operation. By providing precise and reliable data without halting production, Flexco Elevate® helps improve safety, reduce long-term maintenance costs, and support operational reliability and sustainability.
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