Optimizing Mining Operations for Maximum Reliability

Prevent Operational Losses and Ensure Continuity

In mining, every minute of downtime counts. Equipment failures not only impact production but also incur significant costs. Reliability is key to maintaining efficiency, safety, and profitability in harsh and challenging environments.

Critical machines which require constant monitoring to avoid unexpected breakdowns :

  • Crushers, conveyors, belts, mills, pumps, haul trucks, shovels, and stacker reclaimers

Factors and challenging environments such as ATEX zones, dust, long distances creating difficulties to access equipment or transmit data, and problems in monitoring high-vibration and mobile equipment further complicate operations.

  • Protect Production Output: Avoid halts in operations that disrupt supply chains.
  • Reduce Maintenance Costs: Save millions by detecting faults early.
  • Improve Resource Management: Plan maintenance to minimize impact on production schedules and maximize uptime.
  • Enhance Safety : Ensure the well-being of personnel by identifying risks early and reducing exposure to dangerous environments.

Mining Reliability

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years of experience

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km of conveyors monitored

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with NEST Vision combining alignment, vibration, oil, thermography, and more Actionable data 24/7

Anticipation: Our Condition Monitoring Advantage

Stay Ahead with Acoem’s Technology

Through advanced monitoring systems, detect issues before they disrupt mining operations:

  • Wireless Monitoring: Seamless installation for conveyor belts and mobile equipment.
  • Fiber Optics Monitoring System: Robust solutions for both data transmission and equipment monitoring over extended distances.
  • Real-Time Insights: Early fault detection minimizes downtime.
  • NEST Vision:  A comprehensive monitoring solution combining portability, wireless capabilities, and online real-time data analysis to ensure maximum flexibility and efficiency. All in one (portable, wireless, online)
  • Accurex AI : Acoem’s cutting-edge AI-powered diagnostic technology, leveraging expert-approved data to deliver precise, automated fault detection and actionable maintenance insights.

Discover Accurex™

 

Mining-Specific Monitoring Solutions : Innovative Tools for Maximum Reliability

  • Acoem MCT™ (Machine Condition Tracking): Designed for use with Eagle and MV-x systems to monitor equipment in dynamic environments, such as rotary car dumpers, mobile machinery, and conveyors. Wireless technology built to withstand the demands of harsh mining conditions.
  • Smart Anomaly Detection AI: Cutting-edge analytics for precise fault identification and prediction, minimizing unplanned downtime.
  • Shock Finder™: Quickly detects abnormal vibration patterns, enabling immediate corrective actions to prevent equipment failures.

Discover the case study about Elevating Mining Efficiency : Acoem’s Eagle takes flight in Brazilian Port Operations

 

 

Maximize Your Savings with Acoem : Achieve Measurable Impact

1.

Quick ROI

1. Quick ROI

Achieve ROI in under 3 months, save a lot with fault detected early.

2.

Increased Equipment Lifespan

2. Increased Equipment Lifespan

Extend asset life by 20%.

4.

Reduced Downtime

4. Reduced Downtime

Avoid significant productivity losses with early fault detection.

3.

Lower Maintenance Costs

3. Lower Maintenance Costs

Reduce unnecessary interventions by up to 30%. Save up with fault avoided by focusing on critical repairs.

Trusted Solutions for Critical Mining Applications

Rotary car dumpers endure slow, cyclical rotations and heavy shocks while unloading materials, making traditional wiring inefficient and costly in harsh conditions. Failures can cause significant downtime and impact productivity.

  • MV-x & Eagle MCT™ wireless sensors – Monitor vibrations and mechanical forces in real-time, detecting early signs of fatigue and misalignment during slow, transitional movements.
  • Resilient in extreme conditions – Built to operate reliably in harsh mining environments, with continuous, real-time monitoring.
  • Proactive diagnostics – Data analysis helps identify potential malfunctions early, enabling efficient maintenance scheduling and minimizing downtime.

Result: Maximized uptime, reduced failure risks, and optimized material flow in mining operations.

Discover How ACOEM’s MVX Helped VALE Save 7.8 MUS$

Mining conveyors span kilometers in extreme conditions—rugged terrain, dust, and temperature extremes make maintenance challenging. Traditional wired systems are too expensive and impractical: cabling over such distances is costly, difficult to install, and prone to damage.

  • Wireless sensors – Continuous vibration and temperature monitoring, even when idle. No need for complex, high-maintenance cabling.
  • Fiber optic technology – Detects anomalies across the entire length, ensuring early fault detection in harsh environments.

Result: Reliable monitoring, fewer failures, and uninterrupted operations—without the limitations of wired systems.

Check out our case study about transforming the operations of a Brazilian mining port with Sparrow and NEST Vision 

Vibrating screens endure intense vibrations and operate in remote locations, making wired monitoring too costly and impractical over long distances. Without early detection, structural fatigue and component wear lead to unplanned shutdowns.

  • Sparrow wireless sensors – Capture multiaxial vibrations in real-time, even in extreme conditions. No expensive cabling required.
  • AI diagnostics – Detects faults early, preventing failures and costly downtime.
  • Instant alerts – Operators take action before minor issues become critical.

Result: More uptime, longer equipment life, and lower maintenance costs.

Find more about Sparrow taking flight in Gold Mining

Mining excavators are mobile and operate in dynamic environments, making traditional wired monitoring impractical and costly. Sudden mechanical failures can lead to expensive downtime and major production losses.

  • Eagle MCT™ & MV-x wireless sensors – Monitor vibrations and temperatures in real-time across critical components, even as excavators move.
  • AI diagnostics – Detect early signs of wear, imbalance, or misalignment, preventing costly breakdowns.
  • Proactive maintenance – Data-driven insights enable timely repairs, reducing unplanned downtime.

Result: Enhanced safety, fewer breakdowns, and maximized productivity with wireless, real-time monitoring.

Discover the case study about : Elevating Mining Efficiency: Acoem’s EAGLE Takes Flight in Brazilian Port Operations

Reclaimers are complex, heavy-duty machines with high mechanical stress, making them difficult to monitor with traditional wired systems.

  • MV-x wireless sensors – Monitor vibrations and mechanical forces in real-time, even in challenging, dynamic conditions.
  • Advanced diagnostics – Early detection of wear, misalignment, and fatigue, preventing costly failures.
  • Reliable in harsh environments – Ensures continuous, efficient monitoring without the need for extensive cabling.

Result: Increased reliability, reduced downtime, and optimized performance for reclaimers in mining.

Discover how to Optimize Reclaimers Reliability in Open-It Mining

Advisor Turnkey Services

Remote Expertise for Faster, Smarter Decisions

Get real-time insights and instant expert recommendations without the need for costly and time-consuming travel. Our remote diagnostic services ensure that you receive rapid and accurate advice from certified experts anytime, anywhere.

  • Remote diagnostics – Experts provide instant feedback and tailored solutions, reducing downtime and improving decision-making.
  • Wireless monitoring – Continuous, real-time data collection allows for quicker, more accurate analysis without the need for complex cabling.
  • Global support – Experts available remotely from Brazil, India, Thailand, France, and the US, ready to assist with your mining needs.

Learn more about Advisor

Can we avoid misalignment failure?

We offer the next-gen proactive maintenance solution

Acoem’s proactive maintenance approach focuses on the root cause of failures and scheduling pre-emptive maintenance to extend the life of your complex mining machinery. The AT-200 is the ideal entry-level, budget-conscious system for shaft alignment of simpler elements like pumps and gearboxes. The AT-300 is more suited to alignment and vibration management of critical machinery and the top-of-the-line AT-400 is the best option for white metal (film) bearings and heavy load assets like wind turbines used for mine site power generation, as well as geometric and cardan shaft alignment.

AT-200

The smart app-based shaft alignment solution

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AT-300

Next-generation digital line laser system redefining precision and productivity in measuring methods.

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AT-400

Achieve precision with the Acoem AT-400 high-end dual-axis shaft alignment system.

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Laser geometric alignment tools

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Detect and Correct “Unbalance” Issues with Falcon

Let our AI solution put you at ease

Unbalance in critical assets can lead to excessive wear, energy loss, and costly downtime. The Falcon is designed to detect and correct imbalance before it impacts your machinery.

Using advanced vibration analysis, Falcon identifies the source and severity of unbalance, helping you target and fix the issue quickly. With real-time diagnostics, it ensures that your equipment remains in optimal balance and minimizes vibration-induced wear.

They trust Acoem

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