Conveyor belt tracker with real-time monitoring

conveyor belt tracking & monitoring

Introducing SmartSAT™, the next-generation belt alignment solution that combines the proven mechanical performance of the Sure-Align Tracker (S.A.T) with cutting-edge sensor technology powered by Vayeron. Designed to deliver real-time conveyor tracking data and predictive maintenance insights, SmartSAT is your all-in-one answer to reducing downtime, increasing safety, and optimising conveyor performance.

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SmartSAT™

Product breakdown

Vayeron Gateway embedded on the tracker via frame mounting
Vayeron Gateway can be networked via cellular network, ethernet or fibre communications
Rubber lagged conveyor belt steering rollers
Cross link
Heavy duty guide roller
Tilt sensor located on the tracker pivot point
RF antenna to communicate with Tracker’s embedded smart rollers
using the Vayeron Smart Idler® sensor technology
Heavy duty guide roller
Cast pivot members
conveyor belt tracking & monitoring

Challenge or Goal

Tracking conveyor belt alignment
Detecting tracking issues early
Preventing roller-related failures
Reducing downtime and unplanned maintenance
Managing costs from wear, lagging damage, etc.
Implementing smart infrastructure
Data-driven maintenance planning

SmartSAT™ Benefit

Real-time digital tracking signature for diagnostic insights
Continuous angular feedback from tilt sensors
Condition monitoring of lagging and bearing health
Alerts before failure modes occur (e.g., bearing seize)
Early intervention before tracker or belt damage escalates
Acts as gateway node for future smart roller expansion
Provides high-resolution belt and roller condition history

Applications

mining
Aggregates
cement
power generation
Aggregates
Bulk Material Handling Facilities
mining
Aggregates
cement
power generation
Aggregates
Bulk Material Handling Facilities

Future-Proof Your Conveyor System

SmartSAT™ isn’t just an upgrade—it’s a transformation. Start solving belt alignment problems today, and build the foundation for intelligent, connected conveyors of tomorrow.

The SmartSAT™ is not just a passive mechanical tracker—it’s a smart conveyor insight platform. By combining advanced sensor technology with the rugged mechanical advantages of the S.A.T, it transforms conveyor maintenance from reactive to proactive.

It addresses the industry-wide problem of unpredictable belt misalignment and roller failures, which, lead to spillage, belt wear, downtime, and safety risks. SmartSAT combats these with real-time data, early warnings, and a foundation for broader IoT integration in bulk material handling operations.

It’s a dual-purpose investment:

  • Immediate benefit: Improved belt alignment and tracking efficiency.
  • Future-proofing: Readiness for full smart roller network implementation without duplicating infrastructure.

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For more information or to request a demo, contact us at:

Syntron Material Handling
Vayeron

This field is for validation purposes and should be left unchanged.

Open Cut Metalliferous Mine

Outcome: 34 times Return on Investment (ROI)
Saved 375 man hours on labour

BEFORE INSTALLING SMART-IDLER®

Roller Related Expenses Year 1 Year 2 Year 3 Year 4
Annual conveyor roller incident costs $1,294,780 $1,294,780 $1,294,780 $1,294,780
Annual conveyor belt crew labour for rollers $48,913 $48,913 $48,913 $48,913
Annual conveyor roller replacement costs $1,250 $1,250 $1,250 $1,250
Annual roller related expenses $1,344,810 $1,344,810 $1,344,810 $1,344,810

AFTER INSTALLING SMART-IDLER®

Roller Related Expenses Year 1 Year 2 Year 3 Year 4
Annual conveyor roller incident costs $0 $0 $0 $0
Annual conveyor belt crew labour for rollers $0 $0 $0 $0
Annual conveyor roller replacement costs $24,600 $2,201 $2,201 $2,201
Annual software cost to manage smart idler $15,000 $15,000 $15,000 $15,000
Annual roller related expenses $39,600 $39,600 $39,600 $39,600

In this instance the mine spent $$39,600 and saved $1.3M = ROI of 34 times their investment

Return on Investment - Payback Period

Return on Investment Year 1 Year 2 Year 3 Year 4
Vayeron Return on Investment Multiple 33.9 78.2 78.2 78.2
Time to payback (months) 0.5 0.1  0.1  0.1

Year 1 Year 2 Year 3 Year 4
ROI multiple if we price in catastrophic risk 78.2 349 349 349
Time to payback (months) 0.2 0  0  0
Reduction in Risk Exposure (man hours) 375 375 375 375