Innovation

A doctor for conveyors and sorters?

We all know regular trips to the doctor are important – but routine health checkups and specialized care are just as critical for machinery as they are for humans. Our recent test of predictive maintenance tools with audio AI yielded promising results. Let’s see what the conveyor-belt doctor had to say.

Learning to listen more closely

When you visit the doctor, what’s the one medical device you’re most likely to see? The stethoscope. This simple tool, which has been in use for over 200 years, can reveal powerful insights about your health – a flutter, a murmur, or an irregular rhythm. It listens for what the eye can’t see. Now imagine applying that same principle to the heart of a logistics operation.

Sorting systems are the lifeblood of busy logistics hubs, with complex networks of conveyor belts moving shipments like a circulatory system transports blood cells. But like the human body, even the most robust system can develop issues over time. Routine inspections help, but by the time our mechanical “patient” shows symptoms visible to the human eye, it may already be too late.

What if we could listen in on our machines in real time – like a permanent doctor with a stethoscope – picking up the earliest signs of trouble?

That’s exactly what our forward-looking team at DHL Customer Solutions & Innovation (CSI) set out to test in collaboration with colleagues from DHL Express Germany. They piloted an Internet of Things (IoT)-powered tool for predictive maintenance. This portable “doctor in a box” is quick to deploy and was first identified during a startup pitch session hosted at the DHL Innovation Center.

A high-tech stethoscope for sorting systems

At first glance, it looks like an ordinary box on the belt. But inside the compact device are advanced sensors and cameras. As it rides through the sorting system, it records video and audio, gathering data for analysis. Its sensors detect vibration, orientation, sound, distance, and light levels. The three HD video cameras and thermal vision provide comprehensive visual coverage every inch of the way.

Unlike permanently installed measuring carts, this compact and mobile “doctor in a box” works across multiple sorter types – from shoe and pop-up sorters to crossbelt systems. Its portability makes it ideal for testing in various DHL hubs. So far, it has successfully measured crossbelt sorters at our new Munich Airport Gateway (MUC-GTW) and a shoe sorter at our Dortmund Service Center (DTM SVC).

A box full of IoT in action

In this video, the IoT-powered tool rides through a sorting system on a conveyor belt and gathers data.

Early diagnosis, fewer disruptions

Conducted at our new DHL Express gateway under construction at Munich Airport, the pilot showed that predictive maintenance powered by audio AI works. The test generated valuable insights that can help prevent downtimes and reduce maintenance costs.

While the technology currently provides early indications rather than definitive diagnoses, it has already proven useful in identifying issues that would otherwise go unnoticed.

Real-world results from the pilot so far include:

Detected critical vibration before go-live at MUC-GTW, allowing teams to fix the issue early and share insights with the equipment vendor.
Identified a 2mm height offset between sorter and chutes at DTM SVC – causing unnecessary strain on parcels and equipment. The maintenance team adjusted the height and continues to monitor related wear points.
Spotted potential damage risks at high sorter speeds when handling parcels of specific dimensions. Thanks to these insights, adjustments were made during refurbishment to lower the risk without impacting throughput.

The portable setup makes it easy to perform regular checkups, helping teams schedule maintenance proactively rather than reacting to breakdowns. By spotting issues like worn-out ball bearings or misalignments early, we can reduce unplanned downtime, extend equipment lifespan, and keep operations running smoothly.

This pilot is part of a broader push to future-proof logistics through AI and emerging tech. Our CSI SmartSolutions IoT team continues to support DHL sites worldwide in testing and scaling innovative tools like this one.

The IoT-powered tool supports our predictive maintenance approach, giving us greater vision through cameras, hearing through noise sensors, and feeling through vibration and temperature sensors.

Ingo Zigelski, Team Lead OPS Systems, DHL Express Germany

Doctor’s orders: What we’ve learned

Early detection saves time and money:
Predictive maintenance catches issues before they escalate.
Simplicity is powerful:
A small, portable device can generate big insights.
Senses make sense:
Combining sound, vision, and vibration data gives a holistic view of machine health.
Tech supports people:
Smart tools reduce the need for emergency interventions, allowing teams to focus on higher-value tasks.
Prevention is scalable:
The solution is easy to deploy and suitable for diverse sorting and conveyor setups.

Together with our Express colleagues, we’re putting innovation into practice, enabling regular checkups and preemptive maintenance to find problems before they become critical.

Cedric Grosch, Sr. Specialist IoT Business Development & Innovation

The conveyor-belt doctor is in – and the outlook for maintenance is good

Like a doctor with a stethoscope, IoT-enabled devices and audio AI technology allow us to listen more closely to the heartbeat of our hubs – and keep these critical sorting systems in peak condition.

The prognosis? Very promising. This test demonstrates once again the potential of IoT in logistics. Encouraged by the results, DHL Express is now planning more pilots at additional sites and exploring initial rollouts of the technology this year.

Predictive maintenance continues to gain traction across DHL Group, with more pilot projects underway to improve data quality and expand coverage. Our team at DHL Express Germany is proud to support this effort, helping turn early insights into scalable innovations that protect our people, equipment, and operations.