In mining and aggregate processing, downtime is a profit killer, and misaligned rotating machinery is one of its leading causes. From crushers and conveyors to dewatering pumps and ventilation fans, precision shaft alignment is critical for keeping operations moving in the most demanding, abrasive conditions.
The X-Series™ Laser Shaft Alignment Systems from Hamar Laser Instruments are built tough for these environments. With wireless laser technology, rugged IP67-rated alignment heads, and real-time data capabilities, they help maintenance teams detect and correct misalignment faster and more accurately than ever before, saving time, extending equipment life, and increasing plant reliability.
Mining and aggregate plants expose equipment to constant vibration, high loads, dust, moisture, and temperature extremes. The X-Series™ is designed to thrive in these conditions:
Whether you’re underground, on a quarry site, or in a remote crushing operation, the X-Series™ performs when and where others fail.
Challenge: A large aggregate producer was battling frequent breakdowns in its primary conveyor motor systems. Misalignment between the motor and gear reducers led to excessive coupling wear, shaft vibration, and bearing failures, especially during peak production months.
Solution: The team adopted the X-660 X-Series™ Laser Shaft Alignment System to assess and realign all conveyor drives across the plant.
Found misalignments
as large as
0.025″ angular error
Alignment time was reduced by more than
60%
Vibration readings decreased by
55%
and coupling life doubled
Annual maintenance savings estimated at
$40,000+
across multiple lines
The site now mandates laser alignment on all new drive installs and motor swaps
With over 53 years in laser alignment and over two decades of field-proven shaft alignment innovation, Hamar Laser Instruments understands what mining operations need: fast, reliable tools that work in the real world. X-Series™ delivers performance that’s unmatched, and service that’s unparalleled.
In harsh, dust-filled environments, equipment alignment must be fast, tough, and accurate. X-Series™ thrives in these conditions, helping teams keep crushers, conveyors, and pumps running smoothly while reducing downtime and energy use.
Assumptions for this example: You have a 480 volt motor drawing 40 amps and operating 8400 hours/year. The Power Factor is .85. Electricity costs $0.06/kWhr. Also assume that the amp draw is measured before and after the alignment and it is found that there is a 1 amp difference.
kW =V* A*PF*1.732/1000
kW =480V* 1A*.85*1.732/1000
kW =.706 = power savings
Savings ($) = operating hours * kW savings * kW cost
Savings ($) = 8400 * .706 * $0.06/kWhr
Savings ($) = 8400 * .706 * $0.06/kWhr
Savings ($) = 355.82
If your plant has 80 similar motors, and if only half of them had the same amount of savings, it would total $355.82 * .5 = $14,232!
The coupling icons next to the data displays show the direction of the misalignment at the coupling and update as you move or shim the motor! You can also zoom in on the coupling to show them in the live display area of the screen.
