BeltGenius ALEX (Alignment Expert) from Voith analyses the alignment of carrying idlers in conveyor systems. As soon as the system sensors detect a deviation from the set values during their temporary measurement, BeltGenius ALEX reports the problem and provides specific solution suggestions. In the first installations, the system greatly reduced idler wear, energy costs, and associated CO2 emissions.• The sensor system detects imprecise belt conveyor alignment and provides specific solution suggestions• Longer operating times for idlers increases production efficiency• Considerable reductions in energy costs in belt conveyor systems.Reliable belt conveyor operation is a key to productivity in mines. Even small deviations from the optimum alignment increase energy consumption and lead to belt mistracking, with considerable material spillage and downtime. In addition, inaccurate alignment increases idler wear. This, in turn, leads again to unscheduled downtimes and high costs for spare parts.Mine operators can avoid such expense and production losses using BeltGenius ALEX, developed by Voith. Voith service employees attach the measuring sensors to the edges of the belt on both sides. These sensors measure the alignment of each individual carrying idler. BeltGenius ALEX digitally measures all data and stores them on an integrated SD card. The sensor system detects exactly which carrying idlers and idler frames are affected and automatically analyses the origin of the problem. During the process, each individual idler seat is measured.The analysis data are listed in a well-organised log that contains specific work instructions. These data include, among other things, information about which idlers are critical, as well as how big an adjustment must be made, in which direction, and how far. The result of the alignment work will be verified by conducting a second measurement run. The operator then receives the current values of the system along with a direct comparison, including an evaluation of the potentially achievable improvements. BeltGenius ALEX has been developed for all conveyor systems with belts thicker than 30 mm.Its high savings potential has been confirmed in an initial pilot run, Voith reports. There was significantly less unscheduled downtime thanks to the sensor-based, high-precision measuring on the conveyor belt. At the same time, energy demand for horizontal material transport fell by more than 10%. Following alignment optimisation, wear on the carrying idlers also decreased considerably, extending their lifetime by one-fifth in this case.ALEX is part of the BeltGenius product family from Voith, which also includes BeltGenius ERIC, a digital twin that can be used by mine operators to view the performance of their belt conveyor systems at any time, allowing them to significantly increase productivity. Additional modules are currently being developed.