With Smart-Idler® you never need to worry about your conveyor rollers again.

  • App Development
  • Certification
  • Commercialisation
  • Electronics Design
  • Embedded Software
  • Industrial Design
  • Manufacturing
  • Server Development
  • System Design
  • UX Design

Smart-Idler® is the world’s first commercial intelligent conveyor monitoring system that embeds sensors within the roller. It predicts roller failures, allowing rollers to be replaced during scheduled maintenance periods, rather than during critical production. Smart-Idler is designed to improve safety, increase productivity and reduce operating costs in mining applications.


Rollers failure is the leading cause of conveyor downtime, costing the Australian mining industry more than ~$1.5B p.a. in lost productivity.

Unlike conventional manual inspection methods, Smart-Idler automatically monitors rollers in real-time, 24/7 and accurately predicts roller failures. Rollers fitted with smart-Idler are completely wireless. They harvest energy from the roller rotation and communicate via a meshed network back to a gateway and the internet. Operators can view the status of their conveyor rollers in real-time via the Smartphone App or Web Server.


Smart-Idler® improves safety, reducing the need for potentially hazardous manual inspections. It also reduces the likelihood of fires caused by failures. This is critical for underground coal mines.

Smart-Idler® increases productivity and reduces costs by allowing failing rollers to be replaced during scheduled maintenance periods rather than during critical production. Smart-Idler has been designed to meet stringent intrinsic safety standards.


The Ingenuity design team has developed all aspects of the Smart-Idler system. This includes electronics, embedded software, enclosures, mechanical items, servers and Apps. Ingenuity has assisted in brand development, securing funding, IP protection and manufacture. Smart-Idler is the winner of a Good Design Gold for the industrial category.

Are you ready to create better together?

Get in touch