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Rema Tip Top

REMA TIP TOP Service Management offers intelligent solutions to increase the profitability and productivity of conveyor systems. At Bauma 2016, the REMA MCube monitoring system was first introduced.

Three years later, the German company says it is supplementing its product and service portfolio via radar-based sensor systems & cloud-based service management with REMA CCube “and thus the digital twin of the real system allow precise monitoring and virtual controlling from the company headquarters, regardless of manual on-site inspections. The worldwide digital networking and monitoring of conveyor systems is in high demand and offers improved availability to operators.”


One of the central challenges in the mining industry is to increase the profitability of the plants, which requires little downtime and long service life. This is where REMA TIP TOP says its service management comes in, offering intelligent solutions to maximise the profitability and productivity of conveyor systems. “Our products REMA MCube and REMA CCube are modern tools for the efficient maintenance of complex systems,” says Thomas Moser, Product Manager at REMA TIP TOP. The systems provide ongoing monitoring or control measurements of critical equipment parameters at regular intervals, depending on customer needs, and can thus make a significant contribution to scheduling maintenance stops and reducing production downtime.

“We want to prevent unplanned downtimes in any case,” said Moser. “In line with our philosophy: avoid anything uncontrollable and control everything unavoidable.” With the modern sensor technology of REMA MCube and the associated software REMA CCube, REMA TIP TOP additionally offers a unique system for predictive monitoring and maintenance of conveyor systems: the digital twin. The customer’s conveyor system is digitally reconstructed with all its details, allowing each individual station of the conveyor process to be remotely monitored and optimised. Thanks to digital and cloud-based monitoring, plant operators can detect and correct critical loads at an early stage to prevent expensive damage or, in the event of premature failure, even entire plant components.

One of the conditions for successful controlling is a detailed sensor technology on the system. Therefore, REMA TIP TOP exclusively offers radar-based measurements of volume, speed and misalignment on the conveyor belt for the first time. “So far, the planning of loading units with volume limitation was difficult as a volume measurement was technically not feasible. Only in the event of major deviations, conventional, mechanical systems gave alert to the operator. A millimetre accurate and versatile monitoring is now possible per radar, which significantly increases the quality and the possibilities of controlling tools such as the digital twin.”

In addition to the lifetime of the system, productivity can also be optimised. REMA MCube’s RFID Belt Rip Detection System can significantly reduce the downtime for unexpected damage, such as a longitudinal rip in the belt. At speeds of up to 15 m/s and ambient temperatures of -40 to +70 degrees Celsius, the RFID antennas detect early belt damage and cause an automatic shutdown of the system. This leads to a reduced damage length and a faster repair – a crucial aspect for ensuring the availability of main conveyor lines and thus the productivity of the entire system.

“Currently, the system is already used worldwide in numerous conveyor systems and is in high demand in all areas of the bulk material industry, such as the cement industry, coal or ore mining. As a global company with over 6,900 employees and more than 150 subsidiaries and affiliates, REMA TIP TOP can provide the proactive maintenance service package in many countries around the world. Regional companies thus benefit from the worldwide experience, while global corporations are receiving a uniform and digitally networked solution of consistent quality for all company divisions and plants.”

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AMSJ April 2022