Monitoring Mining Industry Assets
Advance your mining operations by unlocking real-time insights and expert analysis to prevent failures, protect uptime, and maximize productivity.
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Learn Why UpTime Solutions Is the Condition Monitoring Platform Mining Operators Trust
Our Comprehensive Mining Condition Monitoring Systems
Sensors
UpTime’s wireless sensors provide ultrasound, vibration, and temperature monitoring across the mining industry, from mobile transport equipment to processing equipment and everything in between. Both MistLX and MistEX provide scalable, flexible deployments with extended battery life, while Brick-TS1X adds multi-channel vibration and process monitoring.
Software
UpCastCM™ is a condition monitoring software that turns high-resolution condition data into actionable insight. Using cloud-based analytics, secure DSP processing, and enterprise-grade architecture, our systems ensure accurate diagnostics at scale. Data is organized by asset and prioritized by severity. Our maintenance experts then create reliable maintenance plans so your teams know what to fix, when to fix it, and why.
Experts
Our experienced reliability analysts monitor your data every day to separate actual signals from background noise. With decades of mining experience, they validate findings, set meaningful alarm thresholds, provide root-cause diagnostics, and deliver clear maintenance recommendations that turn wireless condition monitoring into a reliability program.
Complete Condition Visibility
Our MistEX & MistLX offer 3-in-1 monitoring of your vital operation assets.
Ultrasound
Ultrasonic monitoring detects and reveals early-stage anomalies and wear on slow-speed assets. By identifying friction and wear in low-RPM assets, even subtle issues are identified long before they escalate.
Lubrication optimization
Slow-speed bearing faults
Low-frequency vibration monitoring helps detect imbalance, misalignment, and looseness in slow-moving machinery.
IP69-rated
FFT spectrum & waveform
Temperature condition monitoring data reveals early signs of overheating, which is a key indicator of stress or impending asset failure.
Trend analysis
Process correlation
How Our Mining Equipment Condition Monitoring Works
We deliver more than condition monitoring systems. Our team partners with your mining business to build a complete reliability program that integrates seamlessly with your existing workflow.
1. Assess
We begin with a detailed audit of your mining facility to identify critical assets that directly affect production, safety, and operating costs. We then define the monitoring scope to ensure the maximum reliability return before deployment begins.
2. Install
Monitoring systems are quickly installed with minimal disruption to your business. Trained analysts configure alert thresholds so each asset is monitored within the correct performance context from the start.
3. Connect
Sensors securely stream quality data to our UpCastCM platform without complex IT involvement, giving you instant remote visibility into mining asset health on an easy-to-use software.
4. Analyze
Advanced algorithms trigger alerts that send data to experienced analysts for review and early fault identification. You can rest assured you’re receiving vetted and verified alerts, not false alarms.
5. Collaborate
Our reliability experts work alongside your team to interpret findings and provide guidance on actions, strengthening long-term reliability culture and trust in your maintenance program.
Built for Mining Operations With Decades of Proven Real-World Experience
Prescriptive Action
UpTime Solutions goes beyond alarms and trend lines. Our experienced analysts deliver fault-specific diagnostics with severity levels and clear maintenance recommendations.
Our rugged sensors are engineered to perform in extreme conditions, including harsh, cramped environments that are typical for mining sites.
Our sensors provide proven detection on assets operating at slow RPMs. Ideal for conveyors, feeders, crushers, and bulk storage and transfer equipment where early detection might be more difficult.
Proven To Scale
Successfully deployed in both pilot programs and enterprise rollouts, including single-site installations exceeding 20,000 sensors and multi-site mining operations.
We deliver consistent customer paybacks in between 2 and 12 months.
On average, mining organizations experience more than a 30% reduction in total downtime-related costs when integrating our condition monitoring solutions.
Assets We Can Monitor
Experience complete coverage across your mining operations, from material handling to plant reliability and everything in between
Comminution:
- Trunnion bearings
- Inching drives
- Crushers (man shaft bearings, drive gearboxes, eccentric mechanisms)
Conveyors / Material Handling:
- Head & tail pulleys
- Drive gearboxes
- Take-up winches
- Apron and pan feeders
Thickening / Tailings / Water Systems
- Thickener & clarifier rake drives
- Tailings pumps
- Sludge scrapers
Stackers / Reclaimers / Mine-to-Port Assets:
- Slew, luff, and travel drives
- Bucket wheels
- Ship loaders
- Car dumpers
Power & Utilities:
- Gearboxes
- Large motors
- Ventilation fans
- Substations & transformers
- Generators
Proven Performance Across a Variety of Industries
Case Study:
How a leading Fortune 500 company worked with UpTime Solutions to detect faults earlier and
extend asset life.
Situation
The company needed a reliable way to monitor slow-speed equipment, including reducers, gearboxes, and other low-RPM assets. They were mainly relying on reactive maintenance, as their traditional monitoring tools were missing early-stage wear and detection.
Result
- Early detection of a lime kiln reducer operating at 34 RPM, preventing a likely failure within six months.
- Reduced downtime through proactive maintenance scheduling.
- Lower repair costs and extended equipment life due to timely intervention.
- Enhanced reliability culture: the mill now has confidence in monitoring its slow-speed assets and scheduling maintenance with precision.
Problem
- Early-stage faults on slow-speed assets went undetected.
- Limited visibility into reducers, gearboxes, and other critical low-RPM equipment.
- Reactive maintenance allowed room for unplanned downtime and costly repairs.
Solution
UpTime deployed 3-in-1 wireless sensors across the facility to monitor ultrasound, vibration, and temperature in real time.
- Ultrasonic monitoring: Detect friction, gear mesh issues, and bearing wear at low RPMs before vibration signals appear.
- Low-frequency vibration monitoring: Identify imbalance, misalignment, and looseness in slow-moving machines.
- Temperature monitoring: Reveal early signs of overheating to prevent stress or impending failure.
UpTime’s expert analysts helped the team interpret the data and provided prescriptive insights and actionable recommendations.
Result
- Early detection of a lime kiln reducer operating at 34 RPM, preventing a likely failure within six months.
- Reduced downtime through proactive maintenance scheduling.
- Lower repair costs and extended equipment life due to timely intervention.
- Enhanced reliability culture: the mill now has confidence in monitoring its slow-speed assets and scheduling maintenance with precision.
Gain the clarity you deserve
Protect your line’s bottom line by maximizing the ROI on your capital equipment.
Ready to get every ounce of value from your assets? Let’s talk.
