PREMAS® Case Study: Early Detection Helps Prevent Belt Failure

7. October 2026

AUMUND GROUP

AUMUND clamping connection on a bucket elevator belt

PREMAS® Case Study

Early Detection and Timely Action Prevent Belt Failure

Repeated belt drift events detected by PREMAS® 4.0 triggered a timely response, helping to prevent a complete belt failure, unplanned downtime and additional damage.

When operating behaviour changes

Condition monitoring creates value when changes in equipment behaviour are identified early enough to take action. During operation of a bucket elevator, PREMAS® 4.0 detected repeated activations of the belt drift switch. The recurring events required closer attention.

Early warning from PREMAS® 4.0

The repeated belt drift events triggered a PREMAS® 4.0 notification regarding belt stress. Based on this information, the customer and AUMUND Group Field Service aligned on the situation and assessed the need for action.

The notification provided the information needed to respond before the developing condition resulted in a complete failure.

PREMAS® 4.0 dashboard for condition monitoring of a bucket elevator

PREMAS® 4.0 provides continuous insight into key operational parameters of the bucket elevator.

Technician inspecting a bucket elevator belt

Inspection of the bucket elevator following the PREMAS® 4.0 notification.

From notification to action

Shortly after the notification and alignment with AUMUND Field Service, the plant decided to stop the bucket elevator and inspect the belt.

The inspection revealed that the belt was already damaged and that some of the steel cords were broken.

Early detection. Timely action. Belt failure avoided.

Thanks to the PREMAS® 4.0 notification and the customer’s immediate response, a complete belt failure could be avoided – helping to prevent unplanned downtime and additional damage.

Taking condition monitoring further

With AUMUND’s new Clamping Connection Monitoring System (CCMS), online condition monitoring at the clamping connection will be taken to a new level.

Integrated sensors enable critical parameters at the clamping connection to be monitored and analysed even more closely.

Especially in process-critical and large-scale applications, this additional level of monitoring can support maintenance teams in reducing the risk of unplanned downtime and sudden failures.

Technical visualisation of AUMUND Clamping Connection Monitoring System

Technical visualisation of the belt clamping connection and its monitoring components.

From condition data to preventive action

This case shows why early detection matters. Condition data becomes valuable when it gives maintenance teams the opportunity to respond at the right time. By detecting changes in equipment behaviour and triggering timely notifications, PREMAS® 4.0 supports informed maintenance decisions before developing issues turn into major failures.

Learn more about PREMAS®

Discover how PREMAS® supports condition monitoring and preventive maintenance by providing greater transparency into equipment behaviour and enabling timely action.

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