Condition Monitoring in the Conveyor Belt of Europe's Largest Bulk Terminal
Pilot Project with the Sensing Idler at HBTR, HES Bulk Terminal Rotterdam (previously EMO)
The HBTR terminal in Rotterdam – operated by HES International – is Europe’s largest transshipment terminal for bulk materials like iron ore and coal. Its conveyor systems operate around the clock and are a critical part of the (un)loading processes. As such, unexpected downtimes are highly disruptive – particularly in the area of conveyor belts, which often act as operational bottlenecks.
As part of a pilot project, the Sensing Idler – a sensor-equipped carrying roller – was integrated into an existing conveyor system. The project is a collaboration between component manufacturer Artur Küpper GmbH & Co. KG, operator HBTR, and development partner core sensing GmbH.
Project Goals at a Glance
The aim of the collaboration is to test the system under real operating conditions and gather insights for potential future applications. The focus lies on the continuous condition monitoring of carrying rollers to detect wear at an early stage and support maintenance processes with data-driven insights.
- Continued evaluation of the Sensing Idler under real-world conditions
- Monitoring the bearing condition of individual carrying rollers to detect potential failures early
- Gathering data to support the development of condition-based maintenance strategies
Technical Highlights of the Sensing Idler
- Measurement of bearing temperature inside the roller
- Robust sensor integration – protected against dust, moisture, and mechanical impact
- Autonomous power supply with a service life exceeding 5 years
- Solar-powered gateway for wireless connectivity
- Automatic position assignment for quick commissioning
- Mesh network architecture supporting thousands of rollers
- No system modification needed – rollers can be replaced without altering the installation
- Access to condition data via dashboard or system integration
Outlook
This installation is part of our joint efforts to validate the Sensing Idler in an industrial environment and supports our development roadmap. We are pleased that HBTR and Artur Küpper are joining us in advancing innovation in the bulk material sector.
About HES International / HBTR Terminal
With a wide network of terminals, HES International is one of Europe’s leading independent bulk handling companies for both liquid and dry bulk products.
HES Bulk Terminal Rotterdam (HBTR), part of the HES Group, is one of the largest dry bulk terminals in Europe, strategically located in the Port of Rotterdam.
HBTR serves key players in the steel and energy industries and embraces an open-minded approach to technology, continuously exploring new solutions to enhance and future-proof its operations.
About Artur Küpper
Artur Küpper GmbH & Co. KG is a seasoned provider of conveyor system components and rollers, headquartered in Germany. The company is committed to continuously advancing its product range and collaborates with partners to test innovative solutions – such as the Sensing Idler – through selected pilot projects.
About core sensing
Based in Darmstadt, Germany, core sensing GmbH develops intelligent sensor systems for condition monitoring of mechanical components. As Artur Küpper’s development partner, core sensing provides the sensing and data platform for the Sensing Idler and supports its integration into existing system landscapes.
