Conveyor predictive maintenance

Catch conveyor failures before the line stops.

Predictive maintenance for your conveyor systems. Non-invasive sensors watch vibration, temperature, motor load and runtime — and flag the bearing, belt or drive problem weeks before it stops your line.

Prefer to start small? Ask about a single-line deployment.

Built on Google Cloud · installs in minutes · non-invasive · multi-site

What customers see · illustrative
Conveyor health · illustrative
Conveyor drive motor
Vibration trending up
Watch
Belt tension / runtime
Within normal range
Healthy
Take-up bearing
Temperature normal
Healthy

Conveyors fail in ways you can't see — until the line's down.

The hot bearing you find too late

Manual IR-gun rounds and listening surveys miss the bearing heating up between checks; it seizes and takes the drive with it.

Belt tracking & misalignment

Quietly chews the belt edge and idlers for weeks; you catch it after the damage is done.

Motor strain & belt slip

Load creeps up long before a stoppage, with no early signal to act on.

One stop, whole-line cost

Every unplanned stop is emergency labour, expedited parts and lost throughput.

Predictive maintenance on your conveyor in three steps.

1

Mount the sensor

Non-invasive, installed in minutes, no line shutdown, no rewiring.

2

AI watches the machine

Vibration, temperature, AC current/load and runtime, continuously, from day one.

3

Get alerts, work orders & reports

The platform turns the data into action: early warnings, recommended work orders and plain-language reports — across every conveyor and site.

From conveyor signal to scheduled fix.

Bearing & drive health

Vibration and temperature trends flag wear before failure.

Belt slip & motor load

AC current and runtime patterns reveal strain and slip early.

Plant-wide view

Every conveyor and site in one place; the worst-trending line surfaces first.

AI agents don't just chart data — they recommend the fix and the work order.

Real, measured results · 2025

We watched a $31,200 failure happen — with 48 hours of warning on the screen.

In a 2025 deployment at an Ontario building-products manufacturer, IoT Octopus watched a curing-oven conveyor drive motor in silent observation — and saw the bearing failure coming two full days out. This is what inaction costs.

$31,200 CADCost of the failure: $27,000 lost production + $4,200 repairs
48 hoursOf warning visible before the bearing seized
Under $200 CADThe lubrication job that warning pointed to
With alerts on, this is a sub-$200 lubrication job scheduled for the next maintenance window — not a $31,200 line-down event.

Read the full case study →

Background reading: predictive vs. preventive maintenance — which one actually saves money.

Why conveyor teams move to predictive maintenance Illustrative

$10k–$260k / hour

Typical published cost of unplanned manufacturing downtime · illustrative, varies by facility.

~35–45% less downtime

And roughly 70% fewer breakdowns — published predictive-maintenance impact ranges · illustrative.

Weeks of warning

Vibration, temperature and load approaches surface bearing, belt and motor problems weeks before a stoppage · illustrative.

Illustrative industry ranges, not measured Innovate-Ops results. Sources: U.S. DOE / industry predictive-maintenance studies — dornerconveyors.com, ifactoryapp.com.

Built for industrial reliability.

Built on Google Cloud

Secure, scalable infrastructure your IT team can trust.

Non-invasive, minutes to install

No line shutdown and no rewiring to get started.

Multi-site from day one

Every conveyor and site in one place, anonymized at our customers' request.

Manufacturing, warehousing & logistics

Built for the conveyor-driven operations that move product all day.

Conveyor monitoring questions, answered.

How long does installation take?

The device installs in minutes, non-invasively, with no infrastructure upgrade and no production stop. Our team can install it for you as a turnkey deployment, or you can self-install with a guided kit. A photo of the machine's nameplate is enough to get started.

Do I need to shut down the conveyor line to install it?

No. The sensors are non-invasive and mount in minutes — there is no line shutdown and no rewiring to get started.

What signals does it capture?

Standard signals are vibration (the earliest sign of bearing wear, imbalance and looseness), temperature, AC current and load, power usage, runtime and uptime, and the ambient environment. The device also accepts new sensors and custom parameters whenever a process needs them.

How is this different from a CMMS?

A CMMS tracks the work; IoT Octopus tells you what work is needed and when. It watches equipment health continuously and turns its findings into AI recommendations and drafted work orders your team approves. It works alongside an existing CMMS - nothing gets ripped out.

How is our data secured, and where is it stored?

Your equipment data is encrypted in transit and at rest, with per-customer data isolation. The primary data region is Canada, and the platform is built on Google Cloud. You own your data at all times.

Can we start with just one conveyor line?

Yes. Deployments often start with a single critical asset. Monitoring and health verdicts begin on day one from a physics-based baseline; the baseline refines against the machine's real duty cycle over the first weeks, and by month three the asset has a learned profile, fleet benchmarking and monthly reports.

Want the whole picture?

Conveyor monitoring is one part of the platform. Explore how IoT Octopus turns machine data into action across every asset and site.

Book a conveyor demo.

See predictive maintenance running on your conveyor type — vibration, temperature and motor load. Installs in minutes, non-invasive, no line shutdown.

  • Built on Google Cloud
  • Per-customer data isolation
  • Ontario-based
  • A real person follows up within one business day

Real 2025 result: 48 hours of warning before a $31,200 bearing failure at an Ontario building-products manufacturer. Read the case study.

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