Stop sending people up the chute to measure wear
Measuring wear-liner thickness the traditional way means rope access, working at height, confined space, or a full shutdown — and it depends entirely on the judgement of the person holding the gauge. The result is a number that is infrequent, hazardous to obtain, and hard to forecast from.
WearMon is a non-invasive, online wear-monitoring system that bonds directly to the liner material — rubber, metallic, ceramic, polyurethane or polyethylene — and reports remaining thickness continuously.
What it does
- Continuous remaining-thickness measurement at each sensor location, not a periodic gauge reading
- Predictive change-out forecasting — remaining life projected from real wear rate, not a linear assumption
- Shutdown planning — enter your planned shutdown date and the system identifies which liners need changing and how much material to stage
- Inventory accuracy — order what you will actually consume
- Battery-powered, wire-free sensing — no cabling into a moving or wet environment
Where it fits
Crushers, mills, feeders, transfer chutes and screens — any plant where liner wear drives unplanned downtime and where inspection itself carries a safety risk or a production cost.
The operational case
Wear-liner change-outs are one of the largest recurring maintenance costs in a crushing or milling circuit, and they are usually scheduled on fixed intervals rather than on measured condition. Run the interval too long and you risk a failure; change too early and you throw away good steel. Continuous measurement replaces the interval guess with a measured forecast.
WearMon is an instrumentation layer, not a safety-instrumented function. Where it supports an IEC 61511 argument, that argument is about diagnostic coverage and proof-test evidence — a methodology question we will help you frame correctly.
Instrumentation Pilot — 90 days, one critical asset
We instrument one of your critical assets for 90 days and hand you a
defensible condition-monitoring business case — the evidence pack you can take to your own
superintendent. If the data does not justify a rollout, you have lost a project, not a career.
A$4,900 · fixed scope · consultancy-led
Program review, functional-safety gap assessment, sensor installation and a written recommendation.
No infrastructure required on your site.
Frequently asked questions
How do you measure wear-liner thickness without confined-space entry?
WearMon bonds a sensing element directly to the liner material and reports remaining thickness continuously. Nobody has to enter a transfer chute, climb a mill or work at height with a gauge. You get a wear trend and a change-out prediction instead of a single hazardous reading.
Which liner materials does WearMon work with?
WearMon bonds to rubber, metallic, ceramic, polyurethane and polyethylene liners and wear plates. Because the sensing element attaches to the liner itself, the method suits crushers, mills, feeders and transfer chutes rather than being limited to one liner type.
What does WearMon give shutdown planning?
A continuous remaining-thickness trend and a predicted change-out point, so liner replacement is planned from measured wear rather than a fixed interval that either risks a failure or discards good steel.