Nyrstar · Metals & mining
SAM4 detected a developing transmission fault and supplied the trend behind the finding. Nyrstar used the warning to arrange replacement during a scheduled stop. The team’s inspection found a displaced belt and worn pulleys.
Nyrstar’s continuously operating zinc smelter depends on pumps, conveyors, agitators and other critical assets. Unexpected failures could disrupt production and bring maintenance teams back to site at night.
For the pump transmission in this case, early fault information gave the team an opportunity to use a scheduled stop.
Each team makes an active contribution to the maintenance response.
Detect changes in the belt-and-pulley transmission and provide the measured trend behind the finding. Track the indicator through inspection and replacement.
Use the warning to arrange the work during a scheduled stop. Inspect the transmission, identify the physical damage and carry out the replacement.
What SAM4 provided
What the engineering team did
What the information enabledThe warning identified what needed attention. The measured trend substantiated the finding, and Nyrstar used its maintenance schedule to choose when to intervene.
The site used the scheduled maintenance window to replace the affected transmission components. Inspection substantiated the finding, and the published data show the return to normal behaviour after maintenance.
800% ROI Reported over the first 11 months of the Nyrstar programme.
The programme result gives the wider business context. The belt-and-pulley incident above shows one documented decision within that programme; the ROI is not attributed solely to that repair.
Nyrstar is one of Europe’s leading zinc smelters, refining over 300,000 tons of high-purity zinc every year. Operating continuously, the plant relies on pumps, conveyors, agitators, and other critical assets to keep furnaces running. As a vital part of the global zinc supply chain, the company cannot afford unplanned downtime.
Nyrstar installed SAM4 on critical motor-driven equipment. The system measures electrical signals at the motor control cabinet and provides fault findings for the maintenance team to investigate.
Despite a well-established maintenance strategy, Nyrstar faced recurring challenges with unplanned equipment failures. Conveyor stalls and pump seizures caused furnaces to cool, logistics delays, and production losses costing hundreds of thousands of euros per hour.
Maintenance teams were also frequently called out in the middle of the night to respond to urgent breakdowns. The site needed a way to identify risks in advance, reduce reliance on firefighting, and protect critical motors while adapting to evolving workforce needs.
Within just 1.5 months, SAM4 detected misalignment in the belt and pulley transmission for this pump, allowing replacement during a scheduled stop rather than a production-halting breakdown. Inspection revealed the belt had slipped off its pulley and both pulleys were worn. By addressing the issue during a maintenance window, the site avoided an unplanned line stop and potential production loss.
SAM4 data showing belt misalignment and a return to normal behavior after maintenance.
SAM4 has become an essential tool in Nyrstar’s strategy to protect uptime, safety and operational efficiency. In the first eleven months, maintenance shifted from urgent nighttime repairs to scheduled, controlled interventions.
The team used the warning to inspect the transmission and replace damaged components during a scheduled stop.
Start with the equipment and the maintenance question. Discuss the alert information, supporting measurements and engineering support your team would need to make a substantiated call.
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