Bulk material handling digital technology leader

mines    –    ports    –    process plants

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improve the way your facility operates
The most costly component in the conveyor system is the belt.

  • Avoid delays & increased maintenance

  • Improve personnel safety by limiting exposure – Quantifiable hazard exposure reduction.

How?

understand where your roller problems are

Which roller is causing the problem?

Rollers must be inspected whilst still rolling!! This is dangerous!

A Common Scenario Example
Common scenario:

Often batches or ‘zones’ of rollers are replaced all at the same time, when the fact is that only a handful of rollers actually require replacement.

Why?

Unnecessary quantities of rollers are replaced due to the FEAR of future failure events that stop production.

Result:

Adding additional manual handling tasks and elevated exposure to associated injuries for maintenance personnel.

Changing Roller is

dangerous
expensive
stops production
unnecessary if done on a guess
using scarce labour
time consuming
dangerous
expensive
stops production
unnecessary if done on a guess
using scarce labour
time consuming

THERE IS A BETTER WAY…

did you know?

unmitigated risk is high?

Regular catastrophic roller incidents happen globally!

Is your operation at risk?

have you considered

WHAT WOULD A catastrophic failure cost your company?

1 in 50 year event annualised cost 1 in 100 year event annualised cost
 $20M
incident 		  $400,000  $200,000
 $100M
incident		  $2,000,000  $1,000,000

The Vayeron Return on Investment (ROI) is that you mitigate the risk of catastrophic roller failure. Along with saving you labour $ and Downtime $, you can rest assured that your ‘hidden risk’ is mitigated.

What is your annualised cost of carrying this unmitigated risk?

Vayeron Smart-Idler® may allow you negotiate better insurance premiums.

Automation of bulk materials handling systems.

Digitalise your maintenance insights in near real time!

vayeron provides the solution

Produce more tonnes

Optimise your maintenance workflow

Reduce your hazard exposure

  • Access the Vayeron Smart-Idler® Data, streamed direct from your conveyor to your fingertips

  • Integrate with 3rd Party Systems / Software / Equipment on site

  • Better manage the deployment of your maintenance resources

  • Replace only the conveyor rollers that have the detected issues

Managing the rollers in your conveyor system is no longer a ‘cost of doing business’
Now when you identify roller failure, you’re covered with Smart-Idler® Technology.
SMART-IDLER® data-sheet
Gateway data-sheet

How it works

the software

how we integrate into your operation

did you know?

IMPROVED PRODUCTIVITY, SAFETY & MAINTENANCE

Safety
  • Inspect from safety of the control room.
  • Reduce Manual Handling
Reduce Spares/Inventory
  • Use the full life of the idler rollers and save a further 30% – 60%.
Simplified Maintenance
  • Improved operational data and predictive maintenance insight.
  • Optimise preventative maintenance schedules.
  • Change less rollers & use less people.
Prevention of Fires
  • Conveyor Idler failure is the #1 reason for fires. 

Conveyor idler related downtime

Conveyor idler related downtime

Safety
  • Inspect from safety of the control room.
  • Reduce Manual Handling
Reduce Spares/Inventory
  • Use the full life of the idler rollers and save a further 30% – 60%.
Simplified Maintenance
  • Improved operational data and predictive maintenance insight.
  • Optimize preventative maintenance schedules.
  • Change less rollers & use less people.
Prevention of Fires
  • Conveyor Idler failure is the #1 reason for fires. 
COMPARE SMART IDLER TO OTHER INSPECTION METHODS

vayeron in action

use case evidence

Open Cut Mine Case Study – Ore Processing Plant Shuttle Conveyor

With an annual loss of production totalling $1,294,780 plus $48,913 in labour costs this section of the Ore processing plant needed a solution that reduced roller issues and drastically reduced their annualised costs.

vayeron in action

trusted by big business

how we work

pricing structure

At Vayeron we deliver value with the security of a software platform that will help you to mitigate risk, we supply sensors that equip you with the data you need and a support package to help you to eliminate roller related incidents such as:

  • Downtime
  • Fires
  • Belt Damage
Smart Idler Conveyor Smart Site Smart Enterprise Smart
Quantity (Sensors)   1 to 1,000  >1,000 to 5,000 >5,000 to 12,500
 >12,000 
 Data Price per sensor (per month) Contact Vayeron – min 5000 sensors 47% discount on Start Smart   60% discount on Start Smart  P.O.A 
 Support Allowance (included per month) <4 hours  8 hours  16 hours P.O.A 
 Installation & Commissioning
* can be done by mine personnel or 3rd party contractor		  TBA  TBA  TBA TBA 

To order, contact us directly and we will connect you to the right partner or one of our Value Added Resellers.

experts in the field

some of our partners

We are lucky enough to have Multiple Global Conveyor Roller Manufacturers partnering with Vayeron in key regions around the world, who offer their smart roller product ranges to be powered by Vayeron’s Smart-Idler® sensor.

software integrations

value added resellers

make an enquiry

If you would like to discuss how to maximise operational efficiencies and reduce “condition monitoring” operational costs – enquire here and one of our friendly team will be back in contact with you.

Vayeron is a leading Industrial IoT technology company providing solutions to the challenges faced by bulk materials handling processes. Our solutions anchor physical plant & equipment to the digital world.

Our Products
Smart-Idler
3G/4G Field Gateway
End-of-line Verification
Wireless Inclinometer
Bearingbud

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Open Cut Metalliferous Mine

Outcome: 34 times Return on Investment (ROI)
Saved 375 man hours on labour

BEFORE INSTALLING SMART IDLER

Roller Related Expenses Year 1 Year 2 Year 3 Year 4
Annual conveyor roller incident costs $1,294,780 $1,294,780 $1,294,780 $1,294,780
Annual conveyor belt crew labour for rollers $48,913 $48,913 $48,913 $48,913
Annual conveyor roller replacement costs $1,250 $1,250 $1,250 $1,250
Annual roller related expenses $1,344,810 $1,344,810 $1,344,810 $1,344,810

AFTER INSTALLING SMART IDLER

Roller Related Expenses Year 1 Year 2 Year 3 Year 4
Annual conveyor roller incident costs $0 $0 $0 $0
Annual conveyor belt crew labour for rollers $0 $0 $0 $0
Annual conveyor roller replacement costs $24,600 $2,201 $2,201 $2,201
Annual software cost to manage smart idler $15,000 $15,000 $15,000 $15,000
Annual roller related expenses $39,600 $39,600 $39,600 $39,600

In this instance the mine spent $$39,600 and saved $1.3M = ROI of 34 times their investment

Return on Investment - Payback Period

Return on Investment Year 1 Year 2 Year 3 Year 4
Vayeron Return on Investment Multiple 33.9 78.2 78.2 78.2
Time to payback (months) 0.5 0.1  0.1  0.1

Year 1 Year 2 Year 3 Year 4
ROI multiple if we price in catastrophic risk 78.2 349 349 349
Time to payback (months) 0.2 0  0  0
Reduction in Risk Exposure (man hours) 375 375 375 375