Predicting Equipment Failure Before It Happens: Banner Engineering's AMG

Mining is one of the most demanding industrial environments on the planet. The equipment that keeps operations running — conveyor systems, motors, pumps, gearboxes, fans — runs hard, runs hot, and runs continuously. When something fails unexpectedly, the consequences aren't just inconvenient. They're expensive. A single unplanned shutdown can cost tens of thousands of dollars per hour, and in remote mining locations, getting the right technician or replacement part on-site quickly isn't always straightforward.

That's why more mining operations are turning to condition-monitoring solutions — specifically Banner Engineering's Asset Monitoring Gateway (AMG).

What Is the AMG?

The Asset Monitoring Gateway is a hardware-and-software solution from Banner Engineering that provides maintenance and operations teams with real-time visibility into the health and performance of their most critical equipment. It works by connecting to an array of sensors that continuously measure parameters like vibration, temperature, humidity, pressure, and current. That data is then processed, displayed, and — when something looks wrong — it triggers an alert so teams can act before a small problem becomes a catastrophic failure.

Banner offers two AMG versions to suit different operational needs. The AMG with SNAP ID is a wired solution designed for situations where you need to monitor many points on a single asset. It supports up to 20 wired sensors connected via simple M12 cables and features an onboard touchscreen display for local monitoring. The AMG with CLOUD ID, on the other hand, is a wireless solution better suited to facilities or sites where you need to keep an eye on many different assets spread across a large area. It can support up to 40 wireless sensor nodes and feeds data directly into Banner's Cloud Data Services platform, accessible from anywhere via a web browser or mobile device.

Both versions share one standout feature: they require no coding, no special software expertise, and no lengthy commissioning process. The gateways automatically recognize compatible sensors the moment they're connected, enabling teams to go from unboxing to actively monitoring equipment in minutes rather than months.

Why Condition Monitoring Matters in Mining

In mining, the assets being monitored are often massive, mission-critical, and expensive to replace. A conveyor belt motor in an underground coal mine or a slurry pump at a processing facility doesn't get regular check-ups the way a car does. Traditionally, maintenance has been either reactive — fix it when it breaks — or scheduled at fixed intervals regardless of the equipment's actual condition. Both approaches have serious drawbacks. Reactive maintenance means unplanned downtime. Scheduled maintenance means spending money and labor on equipment that may not yet need attention.

Condition monitoring flips both of those models on their head. By continuously tracking real-time data from sensors on the equipment itself, maintenance teams can spot the early warning signs of a developing problem — a gradual rise in vibration levels, a bearing running hotter than usual, a subtle change in motor current — and intervene at exactly the right moment. Maintenance becomes proactive rather than reactive, and it's based on the actual condition of the equipment rather than a calendar.

Banner's AMG supports this approach with VIBE-IQ, a machine-learning algorithm built into the system. VIBE-IQ establishes a unique performance baseline for each piece of monitored equipment over time. Once that baseline is set, the system can detect deviations that might be invisible to the human eye and send an alert via email or text before a fault develops into a failure.

What This Looks Like in Practice

Picture a large-scale mining operation with kilometers of conveyor belts moving ore from the pit to the processing plant. Each conveyor has motors, drive pulleys, and idler rollers — all rotating assets that wear over time. With Banner AMG units deployed along the conveyor system, maintenance teams receive continuous data on vibration and temperature at every critical point. Instead of walking the line on a weekly inspection that may or may not catch a developing bearing failure, the system is watching constantly and will send an alert the moment something changes.

The result is fewer surprise failures, better-planned maintenance windows, longer equipment life, and significant cost savings — exactly the kind of operational gains that mining companies are looking for as they face increasing pressure to maximize productivity and control costs.

In an industry where the ground never stops moving, and the equipment can never afford to stop either, Banner Engineering's AMG and condition-monitoring approach gives mining operations something genuinely valuable: the ability to see trouble coming and get ahead of it.

Local Presence, Regional Power: Inside Process Technology’s Western U.S. Industrial Reach

Process Technology, Inc. has built a reputation in the Western United States as a process partner that understands both the big picture and the details that make industrial systems work reliably every day. Headquartered in Salt Lake City, the company operates across a broad geographic footprint, including the Mountain West, Colorado’s Front Range, and the Southwest. That reach, combined with a deep bench of experienced sales professionals and process engineers, allows Process Technology to deliver practical, technically sound solutions to some of the region’s most demanding industrial markets.

From the outset, Process Technology structured its business around proximity and expertise. Rather than relying on a single central office to serve vast territories, the company maintains multiple locations staffed by engineers and technical specialists who understand local industries, site conditions, and regulatory expectations. This approach shortens response times, strengthens customer relationships, and ensures that equipment recommendations and system designs reflect real-world operating conditions rather than just catalog specifications. Customers see this difference immediately, whether they operate a remote mining site or a high-purity manufacturing facility with tight performance tolerances.

Across the Mountain West, Process Technology supports a diverse industrial base that demands versatility and technical rigor. Mining and mineral processing operations rely on robust, abrasion-resistant equipment that can perform in harsh environments and variable loads. Semiconductor manufacturers in the region require precision, cleanliness, and repeatability at every stage of production. Food and beverage producers focus on sanitary design, consistent quality, and efficient changeovers, while water and wastewater facilities prioritize reliability, regulatory compliance, and long-term lifecycle costs. Chemical processing plants often sit at the intersection of all these requirements, with added emphasis on safety and materials compatibility. Process Technology’s local presence allows its engineers to work directly with plant personnel to select equipment, design integrated systems, and provide ongoing support that keeps operations stable and compliant.

As the company moves east into Colorado’s Front Range, the industrial landscape becomes equally complex, with its own unique challenges. Oil and gas operations demand equipment that can withstand high pressure and extreme temperatures, and that meets evolving emissions standards. Pharmaceutical and biotech manufacturers require validated systems, precise control, and documented performance. Aerospace and defense contractors expect uncompromising quality and traceability, while municipal water systems balance public accountability with aging infrastructure. The region’s rapidly growing craft brewing and beverage sector adds another layer, where consistency, scalability, and energy efficiency matter as much as product flavor. Process Technology’s engineers understand how altitude affects fluid behavior, heat transfer, and equipment performance, and they apply that knowledge to help customers avoid costly oversights while meeting strict regulatory requirements.

In the Southwest, Process Technology works in an environment defined by scale and scarcity. Semiconductor and microelectronics fabrication facilities push the limits of automation, purity, and uptime, often operating around the clock with minimal tolerance for disruption. Large-scale solar energy projects require durable components that perform reliably under intense heat and exposure. Copper mining and refining operations depend on heavy-duty process equipment that withstands corrosive conditions and continuous operation. Municipal infrastructure projects face growing populations and shrinking water resources, while agricultural processing facilities must maximize efficiency in water and energy use. Process Technology’s team understands how desert climates stress equipment and processes, and they design solutions that address water conservation, energy efficiency, and long-term sustainability without sacrificing performance.

What ties all these territories and industries together is Process Technology’s value proposition. The company delivers more than products; it delivers insight. Its process engineers bring deep technical knowledge to complex applications, helping customers navigate tradeoffs between performance, cost, and maintainability. A multi-location footprint enables rapid response, whether that means troubleshooting an unexpected issue or supporting a fast-moving project schedule. Strong relationships with leading equipment manufacturers give customers access to proven technologies and emerging innovations, backed by people who know how to apply them correctly.

Process Technology engineers take the time to understand process objectives, operating constraints, and future expansion plans before recommending equipment or system layouts. That same commitment continues after installation, with ongoing support and troubleshooting throughout the equipment lifecycle. Customers value working with a team that stays engaged long after startup and understands regional environmental standards and regulatory requirements well enough to anticipate changes before they create problems.

Looking ahead, Process Technology continues to evolve alongside the industries it serves. As automation increases, sustainability targets tighten, and supply chains grow more complex, the company invests in technical talent and regional presence to stay ahead of customer needs. By combining local knowledge with broad market experience, Process Technology positions itself not just as a supplier, but as a long-term partner for industrial operators across the Western United States who want solutions that work today and adapt confidently to what comes next.