Intro
Real-Time Insight for Smarter, More Efficient Processing
The size of material on a conveyor belt has a direct impact on how efficiently a plant operates. Crushers, screens, and transfer systems all rely on consistent feed conditions to perform effectively. When particle size drifts outside expected limits, it leads to reduced throughput, increased wear, and unnecessary downtime.
JMB Automation has developed a conveyor-based particle size distribution system that provides real-time visibility of material size directly on the belt. By continuously analysing the conveyed material, the system enables operators to detect changes early, respond quickly, and maintain stable operating conditions.
The Challenge
In many operations, particle size is still assessed using manual inspections or delayed sampling. This approach has a fundamental limitation:
- material conditions change continuously
- issues are only identified after they impact the process
- there is no consistent, objective measurement of feed quality
As a result, problems such as oversize material, excessive fines, or inconsistent feed are often only addressed once they have already caused reduced performance or equipment stress.
The JMB Solution
Our system captures and processes conveyor belt imagery in real time to determine particle size distribution and detect abnormal conditions.
The solution can be deployed in two configurations depending on site requirements:
2D Vision-Based System
- Uses industrial cameras and AI-based image processing
- Detects particle boundaries and estimates size distribution
- Lower cost and simpler deployment
- Well suited for trend monitoring and oversize detection
3D Measurement System
- Uses depth sensing or LiDAR-style technology
- Measures true particle geometry and volume
- Higher accuracy across varying material profiles
- Ideal for detailed analysis and high-value applications
This flexibility allows the system to be tailored to the level of accuracy, cost, and robustness required for each installation.
Turning Data into Useful Information
The system does more than capture images — it converts raw data into actionable insights:
- real-time particle size distribution (coarse, mid, fine fractions)
- detection of oversized rocks and abnormal feed events
- continuous trending of material size over time
- alarms when feed moves outside defined limits
- historical data for shift, production, and maintenance analysis
This gives operators a live understanding of what is actually on the belt, rather than relying on assumptions or delayed feedback.
Impact on Crusher Performance and Wear
One of the most significant benefits of particle size monitoring is its impact on crusher operation.
When feed size is inconsistent or contains excessive oversize material, crushers are forced to operate outside their optimal range. This leads to:
- accelerated wear on liners and internal components
- reduced throughput and efficiency
- increased likelihood of blockages or trips
- more frequent maintenance intervention
By identifying poor feed conditions early, the system allows corrective action before damage occurs.
This shifts the operation from:
- reactive maintenance (fixing wear after it happens)
to - proactive control (preventing the conditions that cause it)
In practical terms, this can extend wear life, reduce downtime, and stabilise crusher performance.
Real-Time Monitoring and Control Support
The system provides continuous feedback to operators and control systems, enabling faster and more informed decision-making.
Typical capabilities include:
- live size distribution dashboards
- oversize detection alarms
- correlation with plant performance (throughput, load, downtime)
- identification of upstream issues such as poor fragmentation or feed variability
This allows operators to respond immediately, rather than waiting for downstream symptoms to appear.
Integration with Plant Systems
The solution is designed to integrate directly into existing plant infrastructure.
It can interface with:
- PLC systems for alarms and interlocks
- SCADA for monitoring and operator visibility
- databases for historical trending and reporting
- web dashboards for remote access and analysis
This ensures the data becomes part of the operational workflow, not just an isolated monitoring tool.
Delivering Practical Outcomes
A conveyor-based particle size distribution system provides measurable operational benefits:
- improved visibility of feed conditions in real time
- reduced crusher wear and maintenance costs
- early detection of oversize and abnormal material
- more stable plant operation and throughput
- better data for continuous improvement and optimisation
Summary
Understanding what is on the conveyor belt is fundamental to controlling the process.
By continuously measuring particle size distribution using either 2D or 3D technology, JMB Automation provides a practical and scalable solution that improves performance, reduces wear, and supports smarter decision-making across the plant.
