Tru-Trac, a leader in conveyor belt tracking solutions, has raised the bar yet again with the successful deployment of its latest Apex Trough Tracker at Richards Bay Coal Terminal (RBCT)—one of the world’s largest coal export facilities located in KwaZulu-Natal, South Africa.
Designed with innovation, safety, and performance in mind, the Apex Trough Tracker is proving to be a game-changer for heavy-duty conveyor systems, delivering faster, safer installations and exceptional belt alignment—without the need for special lifting equipment.
High-Speed, High-Tonnage Challenge
RBCT operates some of the most demanding conveyor systems globally, including 2.2-metre-wide steel-cord belts running at 6.7 metres per second, moving up to 11,000 tonnes of coal per hour. According to Guy Fitt, Sales Manager at Tru-Trac, the site offered the perfect proving ground for the Apex Tracker’s next-generation capabilities.
“We’ve had great success with the Apex range in mining, and we were eager to test its performance on faster and wider belts under harsh conditions. RBCT was the ideal environment,” says Fitt.
Innovative, Lightweight Design
Tru-Trac’s Technical Manager, Gerhard Strydom, explains that the new design features a streamlined steel cradle with cantilever wing rolls and an angle adjustment mechanism beneath the rollers. This design eliminates protruding bolts and reduces weight—enabling faster, more accurate response to belt movement and improved safety during handling.
“Even before the four-week trial ended, the Apex Tracker had dramatically reduced misalignment and eliminated spillage. The performance exceeded expectations, leading RBCT to place orders for additional units,” Strydom noted.
Versatility with Adjustable Wing Rolls
One of the most significant innovations is the tracker’s adjustable wing rolls, which offer flexibility between 10° and 60°, allowing seamless retrofitting across various conveyor systems. When fully lowered, the tracker becomes nearly flat, simplifying storage, handling, and installation.
This is a major advantage for conveyors between 2.1 and 3 metres wide, where conventional installations often require cranes or hoists. The Apex design eliminates that need—cutting installation time by half. At RBCT, the tracker was installed in just over an hour, compared to the usual 2–3 hours in the industry.
Maintenance Made Simple
Maintenance has also been streamlined. The unit’s wing rolls can be dropped, allowing technicians to slide the tracker out and replace it with ease—before readjusting the rolls to the desired angle.
Furthermore, the new design no longer requires space in conveyor hoods or guards to accommodate protruding adjustment rods, removing previous installation restrictions and the need for additional fabrication work or safety approvals.
Rubber Lagging Innovation in the Pipeline
In another strategic move, Tru-Trac is commissioning an in-house injection-moulded rubber lagging system. This will enhance turnaround times, quality control, and performance, delivering better grip and quicker tracking response in the field.
“Our success at RBCT provides a compelling reference for international clients operating high-speed, high-tonnage conveyors—whether in coal or hard rock,” says Strydom. “The Apex Tracker isn’t just an upgrade—it’s a leap forward.”
Conclusion: A Proven Solution for Global Markets
With proven results in one of the toughest industrial environments, Tru-Trac’s Apex Trough Tracker is poised to set a new global standard in conveyor belt alignment. Its versatility, performance, and ease of installation make it the ideal solution for operations seeking to minimize downtime, improve safety, and maximize productivity.
