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Predict Faults & Prevent Breakdowns Before They Happen

Condition Monitoring for Conveyor Belts

Tired of maintenance programs that consume time and budget without preventing failures? UpTime Solutions combines industrial-grade 3-in-1 sensors with intelligent software and expert-led prescriptive analytics to eliminate unplanned downtime in critical motor assets.

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Trusted and Validated by Reliability & Maintenance Professionals

"UpTime Solutions has installed in our facility what is likely the largest wireless installation of its kind in the world – approximately 20,000 sensors over 3 million square feet. Our payback has been tremendous. We estimate a 30% reduction in downtime and a payback period of less than one year. The level of support we receive is tremendous.”
Facility Mgr. & System Maintenance Engineering
Facility Mgr. & System Maintenance EngineeringFortune 500 Material Handling Company
“We looked at several different technologies and we selected UpTime as our vendor of choice because of their demonstrated ability to wirelessly monitor slow-speed assets. We found their solution to be unique in the industry, and they have been very responsive to our needs. We anticipate growing with them over the next several years to cover more and more assets in the future.”
Senior Director of Asset Health
Senior Director of Asset HealthFortune 500 Pulp & Paper Company
“We rely on UpTime Solutions to provide us with detailed actionable intelligence to direct our maintenance work orders. We were looking for a solution that provides us with more than an alert or an alarm. We need to know what specifically is the emerging failure mechanism with a piece of equipment and the timeframe is in which we have to address it. UpTime has provided us with those details, which saves our maintenance team time and money, and creates better floor-level buy-in to support the program.”
Project Engineer
Project EngineerFortune 500 Pulp & Paper Company
“I’ve worked with a lot of predictive maintenance providers during my career. As an independent contractor, I get to choose who I will install and recommend to my clients. The UpTime equipment is the best in terms of capabilities and data quality. I don’t hesitate to recommend them to my clients, and they are experts in their field.”
Owner & Independent ContractorReliability & Maintenance Services

How Does the Belt Condition Monitoring Solution Help Simplify Maintenance Scheduling for Conveyor Belts?

World’s First 3-in-1 Motor Sensors

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In 2019, UpTime introduced the world’s first wireless sensor to combine ultrasonic, vibration, and temperature detection in a single device. Since then, we have continued to elevate performance standards. Today, our technology delivers clear, actionable insights that help keep critical assets operating efficiently while minimizing costly downtime.

Industry-Specialized Expert Analysts

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AI can identify patterns and flag abnormal signatures, but professional industry expertise makes the difference. UpTime’s experienced analysts review every critical alert, diagnose the root cause, and recommend precise corrective actions. With decades of hands-on experience across industries, our team understands conveyor belts and rotating equipment in real-world operating conditions.

Prescriptive Work Orders in Your CMMS

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UpCast integrates seamlessly with your CMMS and EAM systems to strengthen asset visibility and streamline maintenance workflows. Alerts are prioritized and sent directly to your team, complete with prescriptive work orders inside your CMMS. This enables faster planning, better resource allocation, and more efficient repairs.

ISO 9001 & 27001 Certified

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Quality and security guide everything we do. UpTime Solutions holds ISO 9001 and ISO 27001 certifications, demonstrating our commitment to strong quality management processes and rigorous information security standards. You can rely on us to protect your facility’s data while safeguarding your most critical assets.

A Complete Ecosystem Designed for Monitoring Conveyor Belt Health & Function

MistEX & MistLX

Wireless sensors monitor ultrasound, vibration, and temperature, built for scalable deployments and enterprise-wide rollouts.

MistLX: Compact, rugged design with a small form factor for flexible mounting.

MistEX: High-performance model with extended battery life up to five years.

Key features of both models:

  • Bluetooth connectivity to UpCastCM, UpTime’s cloud platform
  • IP69-rated for maximum environmental protection
  • Optional stainless steel housing for wet, high-moisture, or washdown environments

Brick T1SX

Hybrid wireless vibration sensor that integrates existing wired inputs into UpTime’s platform with no batteries or added infrastructure required.

Key Features:

  • Powers and reads up to 15 sensor inputs
  • Converts junction boxes or accelerometers into wireless data hubs
  • Long-range 900 MHz wireless connectivity with no battery replacements
  • Wirelessly transmits data from up to seven accelerometers and seven process channels, plus tachometer input

UpCast

Cloud-based platform that connects all UpTime sensors to deliver real-time vibration, ultrasound, and temperature insights. Intelligent analytics transform data into actionable alerts, prescriptive work orders, and prioritized maintenance activities. Key Features:
  • Highly accurate diagnostics and alerts
  • Prescriptive work orders ranked by severity
  • Easy integration with third-party systems and Active Directory
  • Scalable, enterprise-grade architecture built on Cassandra and MQTT
Learn More About Our Solutions

3-in-1 Condition Monitoring for Conveyor Belts

Featuring MistEX & MistLX – The Ultimate Asset Watchdogs

Ultrasound

Ultrasonic monitoring detects belt and component faults, like bearing wear, pulley issues, or airflow disruptions, weeks or even months before they impact operations. UpTime uses ultrasound as a first line of defense, identifying problems invisible to standard vibration or temperature checks and reducing wasted maintenance effort.

Vibration

Vibration monitoring captures each conveyor’s unique movement patterns, giving a clear view of belt alignment, pulley performance, and roller health. Traditional maintenance schedules can lead to unnecessary downtime or missed issues, but UpTime equips your team to detect early signs of misalignment, wear, or imbalance, preventing unplanned stoppages.

Temperature

Relying solely on thermal trips or overload relays means conveyor issues are often recognized only after heat damage occurs. UpTime’s Mist sensors monitor component temperatures up to 175°F and correlate them with vibration and operational trends. Our platform stores and analyzes these patterns over time, enabling earlier, more accurate detection of hot spots, friction, and potential failures.

Ultrasound Detects

Overheating Conditions

  • Sustained high temperatures in bearings or motors driving the belt
  • Rapid heat rise under standard operational loads
  • Localized hot spots on pulleys or frames

Leak & Flow Analysis

  • Air or gas leaks impacting pneumatic conveyors
  • Steam trap or fluid line failures affecting belt operation
  • Valve bypass or internal flow issues

Electrical Reliability for Conveyor Systems

  • Corona discharge or sparking in high-voltage drive cabinets
  • Electrical arcing and tracking in motorized pulleys or drives
  • Partial discharge patterns indicating early faults

Early-Stage Bearing Wear

  • Sub-sonic friction changes in roller and drive bearings
  • Turbulence or metal-to-metal contact in high-speed idlers
Vibration Detects

Bearing & Roller Health

  • Inner and outer race defects on idler and drive bearings
  • Roller misalignment or excessive wobble
  • Friction increases, indicating lubrication issues

Mechanical Alignment

  • Pulley and roller misalignment, both angular and parallel
  • Soft foot conditions in drive mounts
  • Coupling wear or frame looseness

Structural Integrity

  • Mechanical looseness in conveyor frames
  • Resonance or vibration at critical speeds
  • Foundation or mounting instability

Transmission & Belt Components

  • Gearbox anomalies affecting belt drive
  • Wear patterns on belts and pulleys
  • Vibration transfer from driven equipment
Temperature Detects

Precision Lubrication

  • Acoustic feedback to optimize greasing schedules
  • Detect over-lubrication that increases drag
  • Under-lubrication leading to friction peaks

Bearing Issues

  • Heat buildup from worn or misaligned roller and drive bearings
  • Lubrication breakdown leading to increased friction
  • Temperature spikes that occur before audible signs of wear

Electrical Faults

  • Degradation of motor winding insulation
  • Phase imbalances or single-phasing in drive motors
  • High-resistance connections causing overheating or reduced performance

Load & Process Problems

  • Conveyors operating above or below design load
  • Misalignment between driven and drive equipment
  • Increased torque from changes in material load or process conditions

How To Sign Up for a Pilot Trial of Our Conveyor Belt Condition Monitoring System

On average, our customers see payback within 2–12 months and experience more than a 3x reduction in unplanned conveyor downtime. Ready to see the results for yourself? Try our pilot.

Reliability Assessment

Work with our team to evaluate whether our conveyor belt condition monitoring system is the right fit for your facility.

Installation & Setup

We arrive on-site with everything needed to install and configure your conveyor monitoring sensors and software.

Expert Support & Review

Our analysts track your conveyor assets, issue alerts and prescriptive work orders for abnormal readings, and provide monthly consultations to help optimize your maintenance program.

Industries We Support with Conveyor Belt Condition Monitoring Solutions

Pulp & Paper

Wireless Condition Monitoring
for Pulp & Paper

High humidity, abrasive materials, and non-stop equipment demands are just part of daily life in pulp and paper facilities. These conditions put machinery—like presses, rollers, and conveyors—at risk of overheating, misalignment, and wear.

UpTime’s wireless condition monitoring provides real-time insights into equipment health, helping you avoid breakdowns, extend machinery life, and keep production on track—even in the harshest conditions.

Industrial

Wireless Condition Monitoring
for Industrial

Industrial equipment in refineries, distribution centers, and wastewater treatment plants works continuously under heavy demands. Complex machinery setups, frequent start-stop cycles, overworked motors, and unplanned downtime can quickly disrupt operations.

UpTime’s wireless condition monitoring spots early warning signs of trouble—like rising temperatures or abnormal vibrations—so you can resolve issues before they escalate and keep productivity high.

Logistics

Wireless Condition Monitoring
for Logistics

Every second counts in logistics, where seamless workflows and on-time deliveries are non-negotiable. But conveyor systems and automated equipment are prone to breakdowns and interference from foreign object debris (FOD).

UpTime’s wireless condition monitoring solutions provide proactive monitoring to detect misalignments, FOD, overheating, or other issues early—helping you avoid delays and keep your supply chain moving seamlessly.

Mining

Wireless Condition Monitoring
for Mining

Mining operations push heavy-duty machinery to the limit, with heavy loads, harsh environments, slow-moving components, and relentless schedules. Unplanned downtime not only halts production but can also put worker safety at risk.

UpTime’s wireless condition monitoring solutions help you catch problems early—like worn bearings, overheating components, or abnormal vibrations—so your equipment stays reliable, and your teams stay safe.

Food & Beverage

Wireless Condition Monitoring
for Food & Beverage

In food and beverage production, even minor equipment failures can ripple into major delays, lost product, or compliance risks.

UpTime’s wireless condition monitoring helps you stay ahead of the curve by detecting issues like air leaks, overheating, or vibration changes before they cause disruptions—keeping your lines moving and your standards high.

Automotive

Wireless Condition Monitoring
for Automotive Manufacturing

Automotive production thrives on speed and precision—but downtime on your production line can throw everything off schedule.

UpTime’s wireless condition monitoring helps you keep pace with demand by identifying potential failures early, such as overheating motors, unbalanced conveyors, or leaks in compressed air systems, so you can maintain uptime and stay ahead.

Pharmaceutical

Wireless Condition Monitoring
for Pharmaceutical Production

Pharmaceutical facilities depend on precision and compliance. Equipment failures, whether in cleanrooms or production lines, can mean wasted product, missed deadlines, or regulatory fines.

UpTime’s wireless condition monitoring gives you the tools to ensure consistent operations by catching issues like rising temperatures, misaligned components, or air leaks before they affect your production.

Consumer Packaged Goods

Wireless Condition Monitoring
for Consumer Packaged Goods

Meeting demand in the CPG industry requires production lines to run smoothly, often at high speeds and with little margin for error. Equipment like conveyors, rotary fillers, and packaging lines face constant strain, increasing the risk of misalignment, overheating, or air leaks.

UpTime’s wireless condition monitoring detects these issues in real time, helping you prevent unplanned downtime, maintain efficiency, and deliver on customer expectations without disruptions.

Power Generation

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

Manufacturing

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

Aerospace

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

Oil & Gas

Wireless Condition Monitoring
for Power Generation

Power generation relies on critical equipment—like turbines, generators, and transformers—running smoothly to meet demand.

UpTime’s wireless condition monitoring tools identify issues such as overheating, abnormal vibrations, and component wear early, ensuring reliable energy production and preventing costly downtime.

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.