The technology available to producers and contractors today is drastically different from what was available 30, 20 or even 10 years ago.
Innovations centered around efficiency, safety and sustainability have been at the forefront of equipment and technological developments over the last several years.
In the world of conveying and material handling equipment, manufacturers are putting forth such developments and are providing new value to end users.
“Industry 4.0, the fourth industrial revolution, is characterized by the integration of digital technologies, automation and data-driven decision-making into manufacturing and industrial processes,” says Paul Ross president and CEO of Douglas-Rulmeca Group. “It leverages advancements in AI, IoT, cloud computing, robotics and big data analytics to create smart, connected and autonomous systems. As these technologies continue to evolve, they will become the norm in the bulk material conveying industry, driving significant improvements in productivity, sustainability and cost savings.”
Predictive monitoring
Two advancements in the conveying and material handling world – and in the construction materials industry as a whole – that are driving equipment development are predictive monitoring and preventive maintenance.
For operations, predictive monitoring offers end users the chance to minimize unplanned downtime and save money as a result.
“One of the most transformative advancements will be predictive maintenance,” Ross says. “Traditional conveyor systems rely on reactive or scheduled maintenance, often leading to unexpected downtime and costly repairs. However, with IoT sensors and AI-powered analytics, companies will soon be able to monitor real-time data on belt tension, motor performance and wear patterns. This capability will enable early detection of potential failures, reducing unplanned shutdowns and increasing operational uptime.”
Kelan Moylan, vice president of sales and marketing at TCI Manufacturing, echoes Ross’s enthusiasm about predictive monitoring. He emphasizes its importance to keep operations running, enhance productivity and improve safety.
“Conveyors can be equipped with control systems that allow for remote monitoring and real-time data,” Moylan says. “The goal for these systems is to allow for predictive maintenance and reduce the need for manual inspections. This not only enhances safety by keeping personnel away from potentially hazardous areas, but [it] also improves overall system reliability.”
Remote monitoring is also something Precision Pulley & Idler (PPI) is paying close attention to of late.
Chris Long, senior product development manager at PPI, says remote monitoring not only offers enhanced insight into equipment health, but it can be utilized as a way for operations to reduce the burden felt due to a lack of employees.
“For example, conveyor systems are commonly being monitored remotely using speed sensors attached to pulley shafts or integrated into idler rolls,” Long says. “These devices alert plant operators instantly in the event of a stoppage or under-speed event, preventing small issues from leading to larger downtime events.”
In Ross’s view, remote monitoring, paired with automation, will continue to revolutionize the industry.
“Cloud-connected conveyor systems and drones, already in use for performance tracking and stockpile monitoring, will expand their capabilities to handle even more critical functions,” Ross says. “These advancements will allow operators to oversee operations remotely, optimizing throughput and energy consumption. Smart conveyors will autonomously adjust speeds and loading rates based on real-time demand, further enhancing efficiency and minimizing energy waste.”