Conveyor systems are critical to material flow, yet failures due to misalignment, belt damage, spillage, jams, or foreign objects cause frequent unplanned downtime. Manual inspection is inherently reactive and often misses early fault indicators, leading to catastrophic belt tears or prolonged production halts. Our vision analytics solution provides continuous, real-time visibility into belt health and material movement, replacing unreliable sensors with intelligent thermal and optical surveillance. This proactive approach identifies faults at the earliest stage, ensuring stable throughput and extending the functional life of critical conveyor networks
Real-time vision analytics for detection of belt misalignment, tears, and wear
Continuous monitoring of material flow to identify jams, spillages, and foreign objects
Automated event alerts with video snapshots for immediate maintenance verification
Identifies belt tracking issues and physical wear before they lead to failure
Jam & Spillage Monitoring:
Real-time tracking of tray conveyors and shuttles to prevent material overflows
Pipe Conveyor Supervision
Detects deformations and opening issues specific to pipe conveyor architectures
Foreign Object Detection
Identifies hazardous debris on belts to prevent downstream equipment damage
Event-Based Smart Alerts
Instant notifications paired with snapshots and video evidence for rapid audit
PLC / SCADA Integration
Seamless data exchange with existing control systems and maintenance software
Downtime Analytics:
Deep-dive historical data to identify recurring failure patterns across the network
Health Dashboards & Trends
Comprehensive visualization of belt performance, fault history, and health scores
Why Faclon Labs
Key strengths behind scalable and production-safe conveyor monitoring deployments
Deep Complex Conveyor Expertise
Experience across diverse systems from standard belts to pipe conveyors
Vision-First Sensor Alternative
Replaces unreliable proximity switches with intelligent visual verification
Zero-Interruption Deployment
Rapid system installation without requiring any production stop pages
AI Tuned for Harsh Environments
Models specifically trained to maintain accuracy in dusty and dark conditions
Vendor-Agnostic Flexibility
No dependency on OEM-locked systems; compatible with any conveyor brand
Secure OT-Compliant Deployment
Enterprise-grade security protocols ensuring safe operation on plant networks
Seamless Scalability
Easily scales from a single critical belt to plant-wide monitoring networks
Integrated Maintenance Workflows
Directly connects detection alerts to actionable repair and upkeep tasks
Proven Industrial References
Successfully validated through large-scale deployments in heavy industries
CASE STUDY - CONVEVOR BELT MONITORING
Driving Operational Stability: Vision Analytics for a Leading Metals Plant
Faclon implemented a vision-based belt, tray, and shuttle conveyor monitoring system at a large metals processing plant to eliminate frequent material jams and misalignment failures. This digital surveillance network provides 24/7 visibility into belt integrity, replacing manual patrols with automated fault detection across critical material handling zones. The system now serves as an early-warning hub, allowing the maintenance team to intervene proactively before minor tracking issues escalate into major production halts
30% Reduction in Conveyor Downtime through real-time jam and misalignment alerts
Early Fault Detection prevented multiple catastrophic belt tears and foreign object damage
Improved Material Flow Stability across high-capacity shuttle and tray conveyor networks
Data-Driven Maintenance Adoption enabled a shift from reactive repairs to scheduled upkeep
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