6 Questions for the Inventor of the HX Belt Monitoring system
Harri Pikkarainen is the inventor of the HX Belt Monitor – a fully automatic, real-time system that optically monitors the entire surface of conveyor belts, from both sides, without any modifications to the belt itself. It detects even the smallest faults early, helps prevent costly unplanned downtime, and improves safety and operational reliability in demanding industrial environments.
1. How did the idea for the HX Belt Monitor come about?
“My background is in optical and laser measurement, both in teaching and research. I was giving a presentation at an event in Kemi, and after the seminar, one of the participants asked if optical measurement techniques could be used to monitor conveyor belt conditions. I immediately understood the challenge they were trying to solve. And I believed a solution could be developed. I had a strong desire to become an entrepreneur, and so the first ideation phase of product development began back in 2007.”
2. What problem were you aiming to solve with this product?
“In many industries, conveyor belts are still monitored visually by workers. There are a lot of belts, they can be extremely long and fast-moving, and the surrounding conditions are often harsh. Manual inspections are neither efficient nor reliable enough for critical belts, which really require continuous monitoring. A serious failure can occur at any time, anywhere along the belt. If a belt suffers critical damage, the consequences can be severe. In mining, for example, material can suddenly move uncontrollably, damaging equipment and posing a serious risk to personnel. Unplanned shutdowns are always expensive.
The HX Belt Monitor inspects the entire belt continuously, 24/7, from both sides, and detects even the smallest changes in belt condition. It performs a 3D optical scan of the surface and automatically monitors for potential faults. This helps anticipate maintenance needs and significantly reduces unplanned downtime. The system also collects valuable data that customers can use to improve their operations over time.”
3. How does the HX Belt Monitor compare to competing solutions?
“Many current systems rely on sensors or metallic wires embedded in the belt, measuring electrical conductivity. However, they don’t cover the entire belt, and installation often has to be done during belt manufacturing. Our system is easily installed afterward and doesn’t require any changes to the belt. It measures 3D deformations across the entire surface and detects early signs of damage. It’s without a doubt the most comprehensive and accurate solution on the market.
Monitoring the condition of a critical conveyor belt can’t rely only on scheduled maintenance. Belt lifespan can end in an instant – a rock or foreign object can damage it at any time. It’s crucial to detect wear and perform timely maintenance before the belt tears over a longer stretch. That way, companies can minimize downtime and reduce safety risks.”
4. Who was the first customer to use the HX Belt Monitor, and where is it used now?
“The first prototype was deployed at the Pyhäsalmi mine in 2008. It was great that they believed in the solution and took the leap with us. The system operated there until the mine closed down.
Today, the HX Belt Monitor is used in 16 countries, with over 100 units delivered to various customers. Around 80% of them are currently operating in mining. Other applications include cement plants, pulp and steel mills, and tunneling operations. Even though we’ve already built a strong track record, the most common reaction from new customers is still: ‘This sounds too good to be true – can it really work on our conveyors?’ Answer is yes! It might sound unbelievable that a unique solution like this, outperforming all competitors, was developed up in northern Finland, on the industrial outskirts of Kemi. But with deep technical expertise, continuous product development, and high-quality collaboration with Roxon, we’re proud to bring this Finnish technology to the global stage.”
5. How do customers benefit from this investment?
“There are many benefits. Once monitoring is automated, human resources are freed from routine inspection tasks. The HX Belt Monitor detects even the smallest issues before they escalate. The return on investment is driven by concrete savings: reduced downtime, longer maintenance intervals, and fewer unnecessary spare parts. And because installation is quick and doesn’t require belt modifications, the investment is easy and fast to implement.”
6. How has the product evolved over the years?
“The core principle hasn’t changed: we optically measure 3D deformations. But the unique way we build the solution and the associated software have developed significantly over the years. Today, 80% of the components are standardized, and installation has been made as easy as possible. The entire system has been optimized to withstand extreme environments – dust, moisture, and freezing temperatures.
This has been achieved through advanced mechanical protection and air flow management. We’ve also developed automatic lens cleaning systems using the same transparent film technology found in F1 driver visors. Customers don’t need to worry whether the system will work underground, where 10,000 tons of iron pellets are constantly swirling and settling into muddy conditions. This product is built for the harshest environments.”