In high-tonnage mining and bulk materials handling operations, conveyor systems are the arteries of production. When they stop, production stops. Yet for years, many operations have managed conveyors in a reactive cycle of breakdown, repair and restart — often at significant cost.
Now, according to conveyor systems specialist Tru-Trac, a growing shift towards structured service level agreements (SLAs) is changing that approach fundamentally. Instead of waiting for failure, operators are increasingly adopting proactive, performance-driven maintenance models designed to optimise reliability, safety and long-term cost efficiency.
Moving Beyond Breakdown Response
In large-scale mining environments, even a short period of conveyor downtime can translate into substantial production losses. Misalignment, belt wander, spillage and premature component wear may appear minor at first, but they can quickly escalate into unscheduled stoppages.
“Production losses alone can run into millions, making conveyor reliability a critical strategic priority,” says AJ van Eyssen, Business Development Manager at Tru-Trac. “Too often, catastrophic failures are not isolated incidents — they are the end result of neglected basics.”
From his field service experience, Van Eyssen explains that most major conveyor breakdowns stem from preventable issues. A lack of routine maintenance can lead to belt misalignment and material carry-back. These problems, if not addressed early, trigger knock-on effects such as idler failure, pulley lagging damage and structural wear.
“It’s a chain reaction,” he says. “One issue leads to another. Before long, you’re dealing with severe component damage, environmental risks from spillage, and unplanned shutdowns.”
The Interconnected Nature of Conveyor Systems
Conveyor systems are highly interconnected. Poor belt tracking can accelerate wear on idlers and pulleys. Carry-back can damage cleaning systems and create build-up along return sections. Structural stress can impact chutes and support frames.
When maintenance is inconsistent or reactive, relatively small defects compound over time. The result is shortened component life, higher repair costs and increased safety risks.
Tru-Trac estimates that up to 60% of conveyor belt performance problems could be mitigated simply by detecting and correcting misalignment early.
“This is where a structured SLA changes the dynamic,” Van Eyssen explains. “With scheduled inspections, ongoing monitoring and planned interventions, you effectively have continuous ‘eyes on the plant’. Problems are identified and addressed before they escalate.”
From Supplier to Strategic Partner
The shift towards SLAs also reflects a broader change in how mines engage with equipment suppliers. Traditionally, procurement in the conveyor sector focused on purchasing individual components — trackers, idlers, scrapers — with system integration and performance management left largely to the operator.
Under the SLA model, however, the relationship becomes more collaborative.
“When components are supplied as standalone products, the responsibility for ensuring optimal performance sits with the mine,” Van Eyssen says. “Our SLA model is different. We’re not there just to sell equipment. We’re there to solve problems and provide a holistic, 360-degree solution.”
Each SLA begins with a comprehensive on-site assessment. Tru-Trac specialists evaluate system performance, identify root causes of inefficiencies and develop a tailored agreement aligned with the operation’s specific conditions and production targets.
Data-Driven Decision Making
For David Pereira, Head of Sales at Tru-Trac, the strategic value of SLAs lies in replacing ad hoc decision-making with structured, data-driven planning.
“The logic behind using SLAs is to move away from reactive maintenance,” Pereira says. “An agreement provides a clear roadmap, predictable costing and measurable performance targets. It allows operators to plan rather than respond.”
Instead of fragmented repairs and emergency interventions, the SLA framework introduces consistent service delivery and continuous improvement. Performance data gathered during inspections informs maintenance schedules and highlights optimisation opportunities.
Given that conveyor belts are high-value assets operating in demanding environments, even marginal efficiency gains can have a measurable impact on productivity and profitability.
Real-World Impact: A DRC Case Study
The benefits of this approach are already visible in the field. A mining customer in the Democratic Republic of Congo (DRC) initially engaged Tru-Trac under a basic SLA arrangement. As results became evident, the agreement evolved into a full maintenance contract.
According to the client’s own operational records, plant availability improved from 65% to over 90% after the implementation of the structured maintenance programme.
Such improvements go beyond reducing stoppages. Higher availability translates directly into increased throughput, improved safety conditions and lower total lifecycle costs for conveyor assets.
A Strategic Shift for Sustainable Production
As mining operations face growing pressure to maximise output, control costs and meet environmental and safety standards, conveyor performance is becoming a board-level concern rather than a purely technical issue.
“The result of a tailored SLA is not just fewer breakdowns,” Van Eyssen concludes. “It’s a conveyor system that runs more efficiently, more safely and at a lower lifecycle cost. That gives mines and processing plants the stability they need to focus on sustained, efficient production.”With conveyor systems forming the backbone of bulk materials handling, the shift from reactive repair to proactive performance optimisation may well define the next phase of operational excellence in the mining sector.