Flexco Elevate | Conveyor Belt Rip Prevention

Stop Downtime with Continuous
Conveyor Monitoring

Prevent catastrophic belt failures and closely observe the health of your belt conveyor systems with Flexco Elevate® Belt Rip Prevention , the intelligent conveyor belt detection system that delivers real-time monitoring and operational insights of your belt without sensors, lasers, cameras, or structural modifications.

Flexco Elevate uses advanced AI technology to keep track of your conveyor belts, detecting and preventing rips and anomalies, automatically shutting down operations in seconds to prevent catastrophic damage. This plug-and-play belt monitoring solution works with any conveyor system, enabling rapid deployment and immediate value for operators in mining, cement, aggregates, and bulk handling.

How Does Rip Prevention Work?

Installation is simple. Mount the Flexco Elevate Belt Rip Prevention device to your conveyor drive, connect power and signals, and activate the system. Most installations are complete in under an hour with no belt modifications, no laser alignment, and no cloud connectivity required.

Once installed, Elevate uses offline AI to analyze motor current signatures and drive characteristics to detect:

- Belt rips before they become catastrophic failures

- Anomalies indicating developing problems

- Material flow patterns and efficiency

- Drive motor conditions and overloads

- Energy consumption and network quality

Data is accessible immediately through the dashboard, providing real-time alerts, trend analysis, and predictive insights to keep your operation running smoothly.

Flexco Elevate is transforming conveyor operations worldwide. Facilities using Elevate have avoided catastrophic belt failures, eliminated costly emergency shutdowns, and gained unprecedented visibility into their conveyor performance.

From early rip detection to predictive maintenance alerts, Elevate delivers measurable cost savings and operational improvements. Discover the real-world impact in our customer success stories below!

Elevate Stops Belt Rip, Prevents £700K Loss

The Cemex UK Dove Holes Quarry, which produces 5 million tons of limestone aggregate annually, installed Flexco Elevate on their most critical production conveyor. When a steel plate fell from equipment above and struck the belt, it detected the anomaly and automatically stopped the conveyor, preventing a complete belt failure that would have resulted in weeks of downtime and catastrophic financial losses.

ELEVATE DASHBOARD OBSERVATION
The system detected anomalous drive conditions when the steel plate struck the belt, triggering an automatic shutdown alert that notified the Cemex maintenance team immediately.

ON-SITE INVESTIGATION
The alert prompted an immediate inspection, which revealed a steel plate from the primary crusher had fallen onto their main production belt. The system had stopped the belt within 12 meters of the impact point, preventing the rip from propagating along the belt.

DIGITAL, PHYSICAL CONNECTION
Had Elevate not been installed to detect the incident, Cemex estimates the belt would have ripped completely in half. With typical belt rip repairs requiring up to 48 hours and downtime costs reaching £20,000 per hour, the single detection event saved the facility between £700,000 and £800,000 in lost production and repair costs.

Elevate Detects Belt Rip, Saves Nickel Operation

A nickel mining operation installed Flexco Elevate on a critical 320-meter fabric conveyor belt running at 2.1 m/s with dual 150 kW motors. When an immediate rip event occurred on the production belt, Elevate® detected the failure and automatically stopped the conveyor, preventing complete belt destruction and protecting downstream equipment from catastrophic damage.

RIPPREVENT+ DASHBOARD OBSERVATION
The system detected sudden changes in the dual-motor drive signatures, indicating a critical belt rip event. Elevate® triggered an automatic shutdown alert and stopped the conveyor immediately, notifying the maintenance team of the anomaly.

ON-SITE INVESTIGATION
The alert prompted an immediate inspection of the 320-meter conveyor belt. Maintenance personnel discovered a rip in the fabric belt that, if left undetected, would have propagated the full length of the conveyor. The immediate shutdown prevented the rip from extending beyond the initial failure point, limiting the damaged section to a repairable area.

DIGITAL, PHYSICAL CONNECTION
Without Elevate installed, the belt would have continued running until complete failure, requiring full belt replacement on the 320-meter conveyor. The early detection allowed for a controlled shutdown and localized repair, preventing the rip from propagating and avoiding the need for a complete belt replacement. The system enabled the operation to return the conveyor to service quickly with a targeted repair instead of facing extended downtime for full belt replacement.

“The system reliably detected a rip event and also a blockage at the transfer point, so it saved us from major damage and longer downtimes.”

BAG

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“The system is extremely easy to install on existing conveyor systems without modifications and offers other useful features in addition to slot monitoring, such as the belt scale function. The mass flow shows a deviation of 1% from the calibrated belt scale and the system has also detected 2 events, thus preventing considerable damage and downtime.”

Salzburger Sand- und Kieswerk

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“The system is installed at several conveyors in our operations and have saved 3x rip events eliminating extensive downtime and material cost. Having the system installed will derisk the business extensively.”

Northern Star Resources

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