Conveyor belts
- Belt misalignment
- Tears and splice failure
- Spillage and carry-back
- Foreign objects on the belt
Prevents: Catastrophic belt loss, conveyor shutdown, material loss
Uptima — equipment lifecycle management
Know what will fail before it does
Uptima watches your machines with sensors and with cameras, on one platform, and tells the right person the moment something changes — whether or not the site has internet.
The problem
The cost of unplanned downtime
Pumps, compressors, generators and heavy machinery fail without warning, and every hour of it costs contracts.
No real-time visibility
Machine health is judged by manual inspection and intuition, not data.
Maintenance is reactive
Teams respond to failures instead of preventing them — always at the worst moment.
No maintenance history
Work orders are paper-based, informal, or lost. Nobody can say what was done last time.
No trend data
Cost per operating hour, uptime percentage and failure patterns are unknown.
And on conveyors and crushers, the most expensive failures are visual. No vibration sensor will ever see a belt tearing.
The approach
Sees and senses
Two monitoring layers on the same asset, reporting one health status. Sensors catch what cameras cannot. Cameras catch what sensors cannot. Between them there is no blind spot — and your team looks at one dashboard, not two systems.
Layer one
Sensors
- Vibration, temperature and motor current sampled continuously
- Pressure, flow, oil level and humidity where the asset calls for it
- Bearing load, oil degradation and electrical imbalance — the failures no camera can see
- Configurable high and low thresholds per machine and per sensor
Layer two
Vision
- Industrial cameras with AI inference running on site, not in the cloud
- Surface wear, material behaviour and structural deterioration
- Novel events with no prior failure signature — things a threshold would never catch
- Annotated still frames attached to every alert
Vision monitoring
Eyes on the asset, 24/7
Industrial cameras trained on the equipment that hurts most when it stops, with the AI running on site so nothing depends on a network link.
Crushers
- Liner wear progression
- Material bridging
- Foreign object ingestion
- Jaw and cone wear patterns
Prevents: Unplanned rebuilds, liner damage, costly mechanical failure
Feeders
- Blockage detection
- Uneven feed distribution
- Structural cracking
- Wear plate degradation
Prevents: Downstream throughput loss, surge events, crusher overload
Flotation cells
- Froth level monitoring
- Froth collapse
- Overflow events
- Air distributor obstruction
Prevents: Recovery rate loss, process upset, reagent waste
Transfer points & chutes
- Material buildup
- Blockage
- Structural wear
- Dust emission
Prevents: Spillage, fire risk, downtime during clearing
How much warning you get
Weeks
Early belt misalignment and crusher liner wear — flagged long before the rebuild threshold.
Hours to days
Belt tear initiation, splice degradation, carry-back buildup and feeder blockages.
Seconds
Foreign objects on a belt or entering a crusher cavity, and flotation froth collapse.
Equipment protection
Automated conveyor stop
Some events do not leave time for a person to react. Where you choose to enable it, Uptima can issue a stop signal directly to your conveyor PLC or motor control centre in under 200 milliseconds of detecting a high-confidence critical event — over a hardwired relay, with no cloud round-trip and no network dependency.
It is an optional capability, configured with your engineering team during commissioning against your own conveyor drive configuration and confidence thresholds.
Events it can act on
- Foreign objects on a belt heading for a transfer point
- Severe belt misalignment, where damage to idlers and structure is imminent
- A detected tear propagating along the belt
- Tramp metal entering a crusher cavity
Safeguards
- Two-frame confirmation before any stop signal is issued
- Confidence threshold configurable per client
- Physical override key-switch on the enclosure for maintenance — state logged
- Manual operator acknowledgement required to restart. Never an automatic restart.
- Every activation logged with timestamp, camera, detection class, confidence and still-frame evidence
Everything else — early misalignment, liner wear, froth anomalies, blockages and level monitoring — raises an alert rather than stopping the belt. Your operators decide which warnings get promoted to stop-armed status.
Alerts
Alerts that reach the person holding the spanner
A dashboard nobody opens prevents nothing. Uptima goes to the channel your team already uses all day, in the language they speak.
- WhatsApp alerts with the still frame attached — the technician sees the fault before touching the machine
- SMS fallback for any mobile number: no smartphone, no data plan required
- Voice call for critical events, in the technician's language
- English, French and Portuguese across chat, SMS and voice
- Unacknowledged critical alerts escalate to a secondary contact
- Reply to an alert to get probable cause and the first three checks to perform
Connectivity
Works without internet
Mine sites, quarries and depots lose signal. Uptima is built for that as the normal case, not the exception — connectivity is a bonus, never a requirement.
- Seven days of readings buffered on site — no data discarded, everything uploaded in order on reconnect
- Vision inference keeps running through an outage; detected events store locally with their still frames
- Automated stop keeps working with no cloud connection — the decision is made on site
- Bandwidth-adaptive sync: full detail on WiFi, summaries on 3G, alert metadata only on 2G
- Multi-bearer connectivity with automatic failover: WiFi, 4G, 2G, satellite
Maintenance
From alert to work order
Detection is only half of it. Uptima closes the loop from the alert to the repair to the record of what it cost you.
- Alerts raise work orders automatically, with photo evidence attached
- Preventive maintenance schedules with reminder alerts
- Parts used, technician and resolution recorded against every job
- Parts inventory with low-stock and reorder reminders
- Uptime percentage and cost per operating hour, per machine
- Downtime cost calculated against your own hourly figures
Enterprise
Built for large operations
Fifty machines or five hundred, across sites and across borders.
Multi-site portfolio
Every site on one map with green, amber and red status. Cross-site comparison and bulk configuration.
Role-based access
Executives, operations managers, technicians, auditors and API consumers each see what they need — and nothing else.
ERP integration
Work orders raised in Uptima sync to your maintenance system as PM orders, over a documented REST API.
Digital twin
A persistent record per machine from installation to decommission, with a remaining-useful-life estimate updated daily.
Audit & compliance
An immutable log of every alert, acknowledgement, work order and configuration change. ISO 55000 and HSE reports export to PDF or Excel.
Energy & ESG
Consumption per machine, carbon footprint per operating hour, and board-ready sustainability reporting.
Deployment
Installed by our own engineers
The same team that services crushers and screens across Botswana commissions the monitoring. You are not handed a box and a manual.
- 01
Site survey
Our engineers review drawings, asset locations and cable routing, then agree camera positions and fields of view with your maintenance team.
- 02
Installation
Cameras mounted, sensors fitted, edge node installed in the MCC room or a weatherproof enclosure. Stop wiring is done here where you've chosen it.
- 03
Calibration
Each camera configured for field of view, exclusion zones, monitoring regions and per-asset detection thresholds.
- 04
Baseline
The system observes your process for 48 hours to learn what normal looks like on your plant before any alert fires.
- 05
Go-live
Thresholds activated, a test alert sent to your team's phones, and the dashboard walked through with your operations manager.
Commissioning and condition monitoring are part of our services.
Talk to us about Uptima
Tell us which assets cost you the most when they stop, and we’ll tell you what monitoring them properly looks like.
Uptima — maximize uptime