The presentation is about a newly, developed method to monitor and optimize belt conveyors, based on a high precision reproduction of the conveyor behaviour using a digital twin. By this numerical reproduction and the continuously performed synchronization between calculation and measuring, the system achieves an unmatched transparency of the belt conveyor’s actual condition. Besides precise information about the overall efficiency, the system delivers early warnings about any changings of the physical state of the conveyor. The generated data allows analysis about time, place and root cause of the changes as well as quantitative statements about the operational properties of the main components in terms of energy efficiency and achievable lifetime. This enables a significant reduction of cost and downtime on the monitored conveyors. In the long run, this approach has the potential to speed up the improvement of the main components. The presentation is interesting for operators, maintenance managers and suppliers of whole belt conveyors or single components.