Stop Losing Millions from Conveyor Belt Failures:
Scops.ai Prevents Downtime in Mining, Steel, and Foundry Plants
Conveyor belts are the lifeblood of any mining or metallurgical operation. In iron and steel foundries, pig iron production plants, and mineral extraction sites, a single failure in the conveyor system can halt production entirely. The cost? Tens or even hundreds of thousands of euros per hour.
May 2025
Yet, despite the obvious risk, most operations still rely on periodic manual inspections and reactive maintenance. This outdated approach leads to catastrophic belt failures, damaged motors, seized ball bearings, misaligned pulleys, and broken shafts, all causing days of unplanned downtime.
The Causes Behind Belt Downtime
- Wear, Misalignments or foreign objects
Cause damage to belts, causing them to tear or break - Over-tensioned or under-tensioned belts reduce life expectancy
- Ball bearing failures
leading to overheating and mechanical seizures - Pulley shaft misalignment
is causing uneven wear and loss of efficiency - Lack of an early warning system
lead to unnoticed gearbox overheating and/or degradation
All of these failures are predictable with the right data.
Why These Problems Still Persist
The reality is that most heavy industrial plants still lack real-time monitoring systems tailored for conveyor infrastructure. Existing condition monitoring setups are either too expensive, too complex to install, or require integration with outdated legacy systems. Maintenance teams are left in the dark until it's too late.
Scops.ai: Real-Time Monitoring Made Simple
With Scops.ai, we solve this problem with a plug-and-play industrial IoT solution built specifically for conveyor belt systems. Our combined approach includes:
Smart wireless sensors
to monitor belt tension, bearing vibration, shaft temperature, gearbox load, and pulley alignment.
Cloud-based software with AI-driven analytics turns raw sensor data into actionable insights.
Fast deployment systems are installed in just a few hours without stopping operations.
Expert remote support to help your team act on alerts before minor issues become catastrophic failures.
How You Benefit
- Prevent unplanned downtime and production losses
- Extend the life of your conveyor system
- Reduce maintenance costs through predictive strategies
- Immediate alerts for mechanical anomalies
- Remote access and wireless data flow, no cabling required
Proven Value for Mining and Metallurgy
A typical mid-sized mining or foundry plant experiences 2–3 major conveyor belt failures per year. Each failure stops production for 1–2 days, leading to:
Lost production ~ €350,000/year
Idle labor ~ €120,000/year (200 employees at ~ €150/day)
Repair costs ~ €100,000/year (€40,000 per incident)
➡ Total: ~ €470,000/year in preventable losses
With Scops.ai's predictive monitoring, you cut this by at least 60%, saving over €280,000 annually.
Who We Support
Whether you're running a copper mine, a pig iron furnace, a continuous caster, or a sand-casting foundry, Scops.ai delivers industrial-grade reliability where it matters most. Our system integrates seamlessly with your maintenance routines and provides the predictive visibility your operation needs.
Mining
iron ore, copper, coal, aggregates
Steel
blast furnace, EAF, rebar, plate mills
Foundries
sand casting, pressure casting, automotive and heavy equipment
Don't wait for the Next Breakdown.
You can prevent €500k/year in losses for a typical plant, without rewiring your site or adding complexity. Let Scops.ai help you catch the failure before it stops you.
Request the full technical whitepaper with ROI breakdowns and real client cases: sales@scops.ai
Scops.ai Solution FAQs
Is Scops.ai kit a hardware or software solution?
Scops.ai is a plug-and-play solution that includes both wireless sensors and software licenses.
Is the kit difficult to configure?
Scops.ai is Plug & Play; we do all the configuration for you. Just power up the gateway, which collects the data from the sensors, and you will be good to go.
How do I start using it?
When you order one of our kits, we will do all the hardware and software initial configurations for you. Upon the arrival of the package, we offer a 20-minute unboxing call with you in which you will connect the gateway, and we will demonstrate how to access and interact with the software.
I am not an expert in analysing data; can I use it?
Yes, Scops.ai is very user-friendly and has already been designed for specific applications. Optionally, we also offer technical support packages where our engineers will support you remotely, so you won't feel lost.
How is data collected? Should I connect it to the company Ethernet or WiFi?
Scops.ai is a completely segregated system designed for maximum cybersecurity. Data is transmitted via LoRa 868 MHz industrial IoT frequency to the gateway, and the gateway transfers the encrypted data to the Scops.ai cloud software via the mobile network using the included industrial SIM card. In this way, Scops.ai works as a segregated field instrument.
I’m interested. Whom should I contact?
You can write to sales@scops.ai, and one of our representatives will contact you to answer any questions and to support your technical needs.
Disclaimer: Based on average industry data. Actual figures vary by plant scale and process type. Estimates include lost production, idle workforce, and typical repair costs for 2–3 events/year.
