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Elements of weakness in commodity import demand may be clearly visible this year, although supportive aspects also are likely to be prominent. World seaborne dry bulk trade growth could decelerate sharply in 2025 as a whole after last year’s expansion.
As an underlying driver, the broad progress of economic activity among countries influencing dry bulk import demand is not showing signs of accelerating from the trend over the past twelve months. A solid pickup in economic growth is not yet foreseeable based on recent signs and assessments by the IMF and OECD. The expected further reductions in policy interest rates, providing a potential boost for activity, seems to be a more extended process than envisaged earlier.
Prospects for world grain trade in the current 2024/25 marketing year ending third quarter 2025 are negative. Updated US Department of Agriculture forecasts published a few weeks ago suggested a steep downturn could occur. The total (wheat, plus corn and other coarse grains) is estimated to fall by 36mt (million tonnes) or 8% from the previous year, to 429mt.
About three-fifths of the global reduction is expected to be concentrated within the East Asia region, as shown in table 1, including wheat in a July/June year and coarse grains in a
October/September year. Weaker imports into the Middle East may contribute another large decrease. Among individual countries the 2024/25 decline envisaged is set to be especially apparent in China, where grain imports may be one-third lower at 41mt, reflecting lower wheat, corn and barley import demand.
Despite vigorous expansion of world coal trade over the past two years, the probability of adverse influences becoming more noticeable in the near future remains valid. The shift towards alternative energy sources is still unfolding in many countries, and a peak in coal trade seems to be approaching.
Over the past two years, a massive 80% rise in China’s seaborne coal imports, from 234mt in 2022, to 421mt in 2024 (based on Clarksons Research data) has underpinned global growth. Elsewhere among all other countries together, a negative trend has been unfolding, with reductions in each of the past two years. It is unclear whether China’s import enlargement will continue in 2025, and perhaps unlikely. This possibility implies flat or lower global coal trade this year.
Similarly, in the iron ore segment, the upturn in world seaborne trade seen over the past two years has reflected China’s import demand growth. The
outlook for the steel industry among raw materials importing countries during the twelve months ahead suggests that there is scope for higher imports by some buyers. But it is not yet certain that these additional volumes will result in a higher overall total.
Iron ore import demand excluding China comprises only about a quarter of the world total, and therefore changes normally have a limited effect. Extra volumes could be seen during 2025 in some of the largest individual countries — Japan, South Korea and the European Union members as a group — but there are no signs at present of strong growth.
Tentative estimates of the large and diversified minor bulk commodity trade segment suggest that growth of around 3% was achieved in 2024, amid higher volumes of industrial commodities. Potential for a further advance this year is visible.
During 2024 the world fleet of bulk carriers continued growing at a steady 3% pace, almost unchanged from that seen in the two preceding years, as shown in table 2. Deadweight capacity reached 1,035m at the end of last year. In the current year, higher newbuilding deliveries may be accompanied by somewhat greater recycling activity, resulting in a maintained fleet growth rate.
source: Clarksons Research (historical data) & BSA 2024 estimate *forecast
In its recent assessment, the Organisation for Economic Co-operation and Development (OECD) confirmed the global economy had been resilient, growth remaining steady and inflation moving downwards, against a backdrop of slower growth, lingering inflation and an uncertain policy environment. Global growth is seen to slow to 3.1% in 2025 and 3% in 2026, with important differences across countries and regions. Inflation is to be higher than previously expected, although still moderating as economic growth softens. However, some signs of weakness have emerged, driven by heightened policy uncertainty. The OECD Secretary-General Mathias Cormann said, “Increasing trade restrictions will contribute to higher costs both for production and consumption. It remains essential to ensure, a wellfunctioning rules-based international
Source: IGC, FAO, USDA-Production-mainly harvested Jul-Dec/Local marketing years
*Argentina, Australia, Canada, US, EU, Kazakhstan, Russia, Ukraine
trading system and to keep markets open.”
The implementation of new tariffs outlined in March are expected to take effect from 2 April. Additionally, the Office of the US Trade Representative (USTR) proposed Section 301 remedies against China’s maritime and shipbuilding sectors, which involves substantial port fees and mandated US vessel usage. This has farreaching, consequences for the agricultural sector, not least because the timeline needed to build new vessels, means US agriculture exports and key agricultural inputs will be disproportionately impacted in the near and mid-term by this proposal. In 2024, the US exported $191bn in agricultural and related products-more than 70% of exports were waterborne and moved by vessels through numerous ports.
The International Grains Council (IGC) provisional forecast for global wheat production in 2025/26 is 807mt (million tonnes), higher than the previous year, and largely driven by a recovery in the EU, with increased sowings — primarily for soft wheat principally in France, Germany and Canada, with lower wheat production expected in major exporting countries including, the US, Russia, reflecting unfavourable conditions across major winter wheat growing regions in the northern hemisphere and below average rainfall outlook in key exporting countries.
USDA project US wheat area to rise to 47m/acres in 2025, with an increase in US winter wheat sowings and a rise in spring wheat acreage, possibly replacing some soybean plantings. Wheat yields to decline year-on-year due to a greater proportion of the crop facing drought conditions compared to last season. Wheat production is forecast slightly lower at 52mt. StatsCan forecast Canada’s wheat acreage to rise to 27.47m/acres in 2025. Much of the increase is for spring wheat 19.42m/acres, with durum wheat 6.36m/acres.
Global wheat production is largely driven by expected gains in the EU 133mt, with increased sowings, primarily for soft wheat, especially in France and Germany. Recent dry conditions in the east, excess rainfall in the west, particularly in France, where in some areas, soils remain waterlogged, may temper gains. In the UK, the winter wheat area is forecast to rebound in 2025, with an upturn in production to12.4mt.
Winter wheat acreage has declined for the third consecutive year. Low soil moisture levels and thin snow cover, raises the risk of frost damage. With the growing season underway in Russia and Ukraine, IGC forecast Russia’s wheat production at 80.6mt. In Kazakhstan, wheat output is forecast c.15mt in 2025/26, lower than last season.
The ongoing war and Russia’s attacks continue to restrict field access and damage Ukraine’s port infrastructure to disrupt agricultural exports. Ukraine’s 2025 winter sown crops have been planted and while rainfall deficits have weakened some yield prospects, the wheat crop is forecast c.22–25mt. Markets have become accustomed to what has become the normal level of attacks on ports and ships in and around the Black Sea.
China’s policy on self-sufficiency in grains and other major agricultural commodities is reflected in the Peoples Republic of China (PRC) food security law that took effect in 2024. Field assessments indicate favourable wheat crop conditions. The crop broke dormancy mid-February in northern areas while in eastern, central areas the crop is making progress, with production c.142mt in 2025/26.
Supported by strong price incentives and government subsidies for inputs-India’s wheat yields to decline slightly, with production unchanged at 113mt in 2025/26. Pakistan’s wheat crop production is forecast at 28mt lower than last year.
Above average soil moisture levels in Queensland and New South Wales expected to support wheat plantings, depending on good rainfall between March and the end of autumn. Abares forecast Australian wheat output at 30.1mt in 2025/26.
The World Meteorological Organization (WMO) forecast a 60% chance conditions will shift to ENSO-neutral (neither El Niño nor La Niña) during March-May 2025 and remain neutral in April–June 2025, suggesting uncertainty with long lead forecasts, are higher than normal.
The forecast for the global wheat crop is a record 797mt in 2024/25. Better crops in Kazakhstan, US, Canada, China, Argentina and Australia, offset smaller crops in Russia 45mt, Ukraine and the EU. Global wheat use is pegged higher at 806mt, feed use
lower at 155mt, food/industry use rising by over 13mt to 651mt. Wheat use increased in Afghanistan, Algeria, Canada, Indonesia, Pakistan and the US.
WHEAT IMPORTS HALVED FOR CHINA AND TURKEY
Global trade is forecast to fall by 17mt to 207mt in 2024/25. This is mainly due to a significant reduction in wheat imports. more than halved in both China to 6.5mt (13.6mt) and Turkey to 4mt (8.9mt); EU 27 imports are also lower at 10.5mt. Russia’s lower wheat outturn 81.6mt, to reduce wheat exports to 45mt in 2024/25 - while other exporters like the US, Kazakhstan, Argentina, and Australia increased exports.
ARGENTINE WHEAT EXPORTS INCREASE IN 2024/25
With smaller wheat harvests, Russia’s exports were reduced to 45mt and Ukraine to 15.5mt, before adopting export quotas on dwindling supplies. Russia’s wheat export duty rising to c.U$28.6/t 12–18 March ’25. Typically, Argentina’s key export market is Brazil. Recent data shows due to the reduced footprint of Russian wheat this year, Argentine wheat exports reached wheat markets in Africa and South/Southeast Asia.
AMPLE WHEAT SUPPLY, LIMITS PRICE SUPPORT
With a smaller Russian wheat crop, the Russian government set a grain export quota of 10.6mt for wheat starting from 15 February to 30 June’25 to ensure available supplies in the domestic market. Global wheat supplies continue to tighten for key exporters, with export quotes converging in March — US 2 HRW $262/t, US 2 SRW $248/t, Russia $247/t, EU Grade1 (Rouen) $248/t, Australia $261/t; Argentine wheat being the most competitive at $241/t (7 March ‘25)
WHEAT STOCKS, LOWEST LEVEL FOR TEN YEARS
USDA forecast global wheat stocks to fall by almost 10mt to 260mt (world 131mt China 129mt), the lowest level since 2015/16 with major exporter stocks likely to fall c.56mt in 2024/25.
AMPLE SUPPLIES, TRADE TENSIONS IMPACT MARKETS
Wheat futures in March, saw significant declines across global markets due to ample supply projections, and recent uncertainty, trade tensions following proposed introduction of US tariffs. MATIF wheat futures in Europe reached a three-
Source: USDA -*Argentine, Australia, Brazil, Canada, EU, Russia, Ukraine, US 1The IGC in January raised their estimate of China’s corn stocks from
by the end of 2017/18
*Major corn
exporters stocks
Source: USDA-*Argentine, Brazil, Ukraine, US
month low. Lower FOB offers for Russian wheat 11.5% $244-$246 FOB, $6 below EU offers. Argentine wheat $246, US SRW $235-$240/t facing higher shipping costs, Ukraine Feed wheat $233/t.
In early March, USDA provisionally forecast, US farmers were likely to reduce acreage for soybeans in favour of an uptick in corn acreage to 94m/acres, a significant increase y/o/y, with an initial forecast for the US corn crop at a record 395mt (15.585m/bu) in 2025/26. Trade estimate acreage is slightly higher at 94.4m/acres.
USDA’s Prospective Plantings report is due end of March, while global weather patterns, remain a critical factor especially for corn production, especially if they arise in China, Brazil or the US, which could squeeze tight global corn stocks.
GLOBAL COARSE GRAIN OUTPUT
1.49BN/T IN 2024/25
Slightly lower than last year and includes a substantial corn crop c.1.21bn, increase in sorghum 61mt and barley c.143.6mt. Smaller outturns in the major exporting countries including, the US, Argentina and Ukraine more than offset by production increases in China and Brazil.
DEMAND RISES FOR FEED, FOOD/BIOFUELS
Global coarse grains use driven by demand for food, feed and biofuels seen rising by 27mt to 1.52bn/t (billion tonnes) in
2024/25. Global trade is expected to fall by 20mt to 223mt mainly due to a steep fall in China’s imports from 48mt to 22mt y/o/y. Coarse grain stocks forecast to fall to 317mt (world 115mt, China 202mt) by the end of 2024/25.
SOUTH AFRICA CORN PROSPECTS IMPROVE
The corn crop is forecast at 16mt in 2024/25, initial estimates suggest a better harvest though prices are lower.
HIGH INPUT COSTS, LOW INTERNATIONAL PRICES OF CORN
Favourable rains in Argentina benefitting the corn crop. The Buenos Aires Grain Exchange (BAGE) estimates the corn crop at 49mt, Rosario Exchange 44.5mt. (USDA50mt). High costs of inputs, rent, compounded by lower international prices is critical for some farmers.
RISING CORN PRICES IN BRAZIL
Brazil’s Centre for Advanced Studies on Applied Economics (Cepea), highlighted buyers are struggling with steep price hikes and logistical challenges in the spot market. As domestic corn prices rise on low stocks, strong demand from ethanol, the livestock industries and weather uncertainty for Brazil’s second corn crop. With Brazil’s first crop harvested c.24.85mt, the focus is on the development of the second ‘Safrinha’ corn crop. Conab pegs Brazil’s total corn crop to reach 122.76mt (USDA 126mt).
GLOBAL CORN CROP FORECAST AT 1.21BN/T
Lower production in major exporting countries-the US, Argentina and Ukraine more than offset increased production for Brazil and China. Corn demand for feed, food and biofuels, is anticipated to rise by 20mt to 1.23bn/t. Feed use to rise by 6.6mt to 779.4mt, food/industry by 13.6mt to 459.8mt. Corn use is seen rising in China by 6mt, Brazil 3mt India 2.9mt and Vietnam 2mt. Changes in feed use to depend on supply and prices of other feed grains.
SLOWER WORLD GROWTH, TO WEIGH ON DEMAND
Increasing industrial use of corn is helped by government programmes in India and Brazil to support farmers increase local corn production. Changes in world feed use to depend on supply, prices of other feed grains. Higher feed use of corn, in response to rising demand for meat and dairy products in Latin America and Asian markets, while slow economic growth, high global inflation, to weigh on demand in some countries.
BIOFUEL DEVELOPMENTS DEPEND ON GOVERNMENT POLICY
The Energy Information Administration (EIA) data shows that US ethanol production hit a record 16.22bn/gallons in 2024, coupled with record exports with 40% to Canada and Mexico and rising domestic consumption, reflecting continued growth in the number of retail stations offering E15, typically priced at significant discount to regular unleaded gasoline and now allowed to be sold all year-round. While corn for ethanol has stabilized-current growth areas are aviation fuel and sustainable diesel, this will depend on the new US administration’s commitment to biofuels.
Corn trade falls by11mt to 187mt, mainly due to a significant corn crop 295mt in China, with less need for imports. Corn stocks are forecast to fall by 25mt to 289mt the lowest level of stocks since 2014/15 (world 88mt,
China 201mt). Major exporters stocks to fall to 44mt with Brazil’s stocks c.3mt by the end of 2024/25. CBOT Corn May Contract closed $4.61/bu (17 Mar ’25).
Despite lower acreage of 46mha, global barley production is forecast at 143.6mt in 2024/25, a slight uptick, helped by improved yields of 3.1/ha. reflecting better crops in the EU 50.4, UK 7.2mt, Kazakhstan 3.8mt and Australia 13.2mt, offsetting reduced output in Russia16.2mt, Canada 8.1mt and Ukraine 5.8mt. Spring planting is strong in the UK 7.5mt and France 11.1mt.
Mainly due to a significant cut in China’s barley imports from 15.9mt to 9.5mt.
Since lifting tariffs on Australian barley in 2023, China imports over 70% of Australian barley and 95% of its sorghum exports in 2024/25. Global barley use is expected to rise to 147mt — with a small increase in feed use to 98.6mt and 48.5mt for other uses. Stocks are drawn-down to 17.9mt. Spring planting strong in the UK 7.5mt and in France 11.1mt. Demand concerns weigh on the outlook for barley.
Due to its drought-resistant properties, global sorghum crop to rise by 3mt to 61mt in 2024/25, with increased output in Nigeria, Argentina and the US. Exports pegged at 6.3mt. China’s sorghum imports are lower at 4.5mt (8.3mt), used mainly for feed and spirit distillation.
Subject to the Prospective Plantings report due end of March, USDA provisionally estimated US farmers to plant soybeans on 83.8m/acres, lower than the previous year, with yields 52.5bu/acre and production 119mt (4.37bn/bu), similar to the current year.
RECORD 679MT OILSEED CROP FORECAST IN 2024/25
Led by soybeans at 421mt with increased output noted for groundnut 51mt, cottonseed 44mt, palm kernel 21mt, copra 6mt-with smaller global crops for sunflower seed 52mt, due to the ongoing war and poor weather in Ukraine; rapeseed 86mt with reduced crops in the EU and Canada.
OILSEED STOCKS RISE IN 2024/25 TO 139MT
With the prospect of a record global oilseed harvest, ending stocks are raised by 7mt in 2024/25 to 139mt (world 91mt China 48mt).
Source: *Brazil and Argentina; USDA/Meal use excl. fishmeal c.5mt
Source: *Brazil and Argentina; USDA
Major exporters stocks are forecast at Brazil 32mt, Argentina 26mt and US 12mt.
GLOBAL OILSEEDS TRADE 208MT IN 2024/25
Increased trade is led by soybean exports of 182mt, partially offset by lower exports of rapeseed and sunflower seed.
Brazil to harvest a record soybean crop of 169mt, Argentina 49mt in 2024/25, despite drought challenges in some areas, lower prices to boost demand for beans, meal and
oil. With large supplies, outpacing potential demand the build-up of South American stocks expected to pressure US domestic prices of newly harvested soybeans from September onwards.
China imposed 100% import tariff, on Canadian canola oil, meal (excluding seeds) and peas, together with a 25% import levy on aquatic products and pork effective 20 March ’25. According to Ole Houe, IKON Commodities in Sydney, “No country really has the scale Canada has. Australia, does not have much surplus or the crushing capacity to significantly raise its rapeseed meal exports”. China’s tariff on canola oil, meal and peas, said to be in response to Canada’s tariff on Chinese electric vehicles and a 25% tariff on steel and aluminium in October ‘24.
The latest forecasts for South America’s soybean harvest season suggests record production for Brazil and Argentina in 2024/25, despite localized drought challenges in some regions.
Brazil’s soybean outturn is expected to reach an all-time high 169mt (Conab 167mt). Argentina’s production 49mt
(Rosario 48.6mt) similar to last season and Paraguay soybeans 10.7mt. Large supplies will exert downward pressure on global soybean prices 2025/26.
RECORD IMPORTS OF BEANS TO CHINA IN APRIL–JUNE ‘25
Analysts, traders confirm China will receive record soybean imports c.31.3mt during April–June ’25 to relieve supply pressure caused by smaller number of arrivals during the Jan–March quarter, when delays in Brazilian shipments, slow customs clearances in China, caused a shortage of supply- Rizhao, a processing hub in China, saw crush margins rise, to over 450 yuan/t ($62.23/t). China is expected to import 109mt of soybeans in 2024/25
OILSEED CRUSHINGS RISE TO 563MT IN 2024/25
Increasing the output of global meal and oil. Feed consumption rising for meals by 14mt to 374mt with increased demand in China, US, Brazil, Vietnam, and Russia. Oil for industry/biofuels rising by 8mt to 226mt.
SOYBEAN IMPORTS LOWER IN 2024/25
China’s soybean imports for 2024/25 forecast 3mt lower at 109mt. Improved weather in South America, and potentially rapid harvest in both Brazil and Argentina, put more supplies into the global market. This coincides with the US government placing additional tariffs on the US top trade partners, causing uncertain demand outlooks. “The US may not lose as much export demand as feared though, as even
USDA: *less than 500,000/t. Meal totals excl. fishmeal
with elevated harvest activity in South America, domestic demand is cutting into export volumes,” said Karl Setzer, Partner with Consus Ag Consulting.
NO ROOM FOR GROWTH IN CHINESE PORK CONSUMPTION
Market prices for beef and pork, over more than 70% of China’s meat consumption, fell to the lowest levels since 2019. Pork, long regarded as a cultural staple and widely consumed, is losing its appeal. Despite significant interventions to prop-up prices, such as purchases of meat for state reserves and revising the optimal sow herd size lower to balance supply against demand.
According to Zhu Zengyong, a researcher with the state-backed Chinese Academy of Agricultural Sciences. Despite the modernization of pig farms, there is no room for growth in Chinese pork
consumption in the near future, due to a weakening economy that led to a surplus. Current demand in China is unlikely to rise further, while falling meat prices will have a negative impact on China’s live cattle and swine inventories where the emphasis is on improving efficiency not expansion in 2025. A rise in the number of breeding sows this year could continue to pressure hog prices Zhu expects the number of pigs slaughtered in 2025 to increase from 2024, while the average price of pigs will decrease by 10% to 20%.
GLOBAL OILSEED STOCKS TO RISE TO 151MT IN 2024/25
Lower prices of soybeans — Argentina (Up River) $404/t FOB (18 Mar ‘25), Brazil (Paranagua) $402/t FOB (18 Mar ‘25), US 2Y (Gulf) $402/t (18 Mar ‘25) CBOT Futures Soyabeans May contract-closed $10.14/bu (18 Mar ’25).
In response to the pressing global need for energy efficiency and decarbonization, OSM Thome has taken a groundbreaking step by establishing a dedicated company named EVIGO, signifying values of strength, energy, and vitality, writes Torbjørn Lie, Business Development Manager, OSM Thome. This new venture is dedicated to innovative strategies aimed at reducing greenhouse gas emissions and promoting environmental stewardship.
One of EVIGO’s key strategies is to co-operate with industry partners and evaluate the alternatives, suitability and adoption of alternative fuels for different vessel segments and trades. It helps customers make more informed alternative fuel strategies for their operations and trade pattern. EVIGO will gather best practice and practical experiences across its customers’ fleets to pave the way for a more sustainable shipping industry.
Another vital component of EVIGO’s approach is the implementation of energy-efficient technologies. These technologies encompass a wide range of innovations designed to optimize energy use and minimize waste. For instance, advanced hull designs that reduce hydrodynamic drag, energy-efficient propulsion systems, retrofitting of energy-saving technologies and optimal hull cleaning plans are just a few examples of how EVIGO is harnessing technology to achieve energy efficiency. By evaluating and proposing a wide selection of solutions, EVIGO not only reduces the environmental footprint for the customer but also enhances efficiency, leading to cost savings.
EVIGO can offer turnkey project management of retrofits, including yard selection, installation and performance monitoring both before and after installation of energy-saving technologies.
EVIGO is committed to aligning with global efforts to achieve netzero emissions. This commitment is reflected in its adoption of best practices for carbon emission reduction. These practices include rigorous monitoring of fuel consumption and emissions, regular maintenance of vessels to ensure optimal performance, and tailor-made training programmes for crew members to ensure eco-friendly operations. Furthermore, EVIGO collaborates with industry partners and regulatory bodies to stay abreast of the latest developments and standards in sustainability. This proactive approach ensures that EVIGO remains at the forefront of environmental innovation in the dry cargo sector.
The establishment of EVIGO marks a significant milestone in OSM Thome’s journey towards sustainability. By creating a separate entity focused solely on environmental stewardship, OSM Thome demonstrates a strong commitment to the future of the maritime industry. EVIGO’s leadership is driven by a vision of a cleaner,
Torbjørn Lie, Business Development Manager, OSM Thome.
greener world where shipping plays a crucial role in achieving global sustainability goals. EVIGO’s strategies for reducing greenhouse gas emissions are a testament to OSM Thome’s dedication to sustainability and innovation. Through the adoption of alternative fuels like hydrogen, biofuels, green methanol and ammonia, the implementation of energy-efficient technologies, and the commitment to best practices in carbon emission reduction, EVIGO is setting new standards for environmental performance in the dry cargo sector. Through its partnerships with industry leading organizations, EVIGO is also involved in paving the way for advanced nuclear in the maritime space. As the world moves towards a net-zero future, EVIGO aims to provide best practice advice, practical solutions and turnkey project capabilities.
In the face of climate change and environmental challenges, EVIGO’s pioneering efforts are a roadmap for a more sustainable and resilient maritime industry. The company embraces innovation, collaboration, and has a steadfast commitment to environmental stewardship. Coupled with hands-on, practical experience across a large fleet of vessels, EVIGO will offer valuable insights and solutions to the dry cargo sector and the wider shipping industry.
The joint venture between Nova Marine and Algoma doubles its investment with China’s Xinle Shipbuilding. The second newbuilding, fully methanol-powered, will start operating for Holcim in 2027.
Nova Algoma — the joint venture between Lugano-based Nova Marine, controlled by the Romeo and Gozzi families, and Canada’s Algoma Central Corporation, a specialist in cement transport — has decided to double its investment with Chinese yard Xinle Shipbuilding in Ningbo by ordering a second record-breaking cement carrier.
As with the first vessel, ordered in July 2024, this newly contracted unit will be the world’s largest pneumatic cement carrier, with a deadweight of 38,000 tonnes. However, unlike its sister ship, which features dual-fuel methanol propulsion, the newbuild will be fully methanol-powered — designed and constructed to run exclusively on green methanol. This solution will allow the vessel to reduce CO2 emissions by more than 60% compared to a conventionally fuelled ship, for the same volume of cement carried. That translates into an estimated 180,000 tonnes of CO2 avoided over ten years of operation.
Scheduled for delivery in 2027, the new vessel will operate on behalf of Holcim — one of the world’s leading building materials producers — under a ten-year time charter agreement already signed.
Both Nova Algoma and Holcim are signatories of the Sea Cargo Charter, an initiative that brings together shipowners and charterers committed to cutting
emissions, improving transparency in reporting, and actively promoting shipping decarbonization as part of a shared environmental responsibility toward a more sustainable maritime industry.
“This is a milestone project for Nova Marine,” commented Vincenzo Romeo,
CEO of the Swiss-Italian shipping and logistics group.
“It reflects our concrete and ongoing commitment to renewing our fleet in key segments and to achieving genuine sustainability in maritime transport and logistics.”
Technology group Wärtsilä will supply replacement engines for two inland waterway tug pusher vessels operating in Paraguayan rivers. The vessels are owned by ADM Naviera Chaco (ADM). The vessel modifications and new engine installations will be carried out in Asuncion-Paraguay. The orders were booked by Wärtsilä in Q2 and Q4 2024.
The new engines will enable a reduction of the environmental impact and increase the efficiency of the tug pushers. ADM’s stated target is to reduce emissions by 25 percent by 2035, and the advanced Wärtsilä engine technology is an important opportunity to advance that effort in South America.
“The Wärtsilä engines selected for this project have the fuel flexibility that we seek, especially as we look to the potential of alternative future fuels. At the same time, the project will help us to improve operational reliability and lower our maintenance costs,” says Raul Valdez, Logistic Director – ADM NAVIERA CHACO S.R.L.
The two vessels covered by this contract are the Decatur Lady and the Tendota. Each will be refitted with three Wärtsilä 20 engines. Delivery of the engines to the shipyard took place earlier this year. The Wärtsilä 20 is a well-proven compact, lightweight marine engine, offering fuel flexibility and reliable performance in genset and main engine applications.
“We are delighted that Wärtsilä engines have been selected for this important project, which highlights the marine industry’s shift to greater sustainability and increased efficiency. ADM’s vision to be the provider of choice to meet the demand for low-carbon intensity feedstocks is very much in line with Wärtsilä’s own commitment to supporting the industry’s decarbonization efforts,” comments Hanno Schoonman, Director of Sales for AMER region — Wärtsilä Marine.
ADM is a global expert in innovative solutions from nature, with a transportation and logistics network that includes 2,500 barges and more than 160 boats.
With the maritime industry in a period of transformation, the safety of crew, vessels, and their surrounding environment has never been more important, write Tatiana Tzeferakou and Eivind Bækkedal, DNV.
Each vessel type has its own particular specifications and in the bulk carrier industry, some unique considerations apply. This ranges from inspections and regulatory compliance to the adoptions of new technologies and fuels related to decarbonization.
In all cases, DNV is utilizing up to date technologies and its decades of experience to ensure that the highest levels of safety are maintained across the bulker fleet.
At a fundamental level, DNV ensures the continued safety of bulk carriers, and compliance with regulations, through scheduled surveys. This requires safe access to inspect critical structural members, a crucial consideration for bulk carriers, especially given their unique structural features.
The International Maritime Organization’s (IMO) MSC.158(78) technical provisions from 2004 ensured that bulker vessels were provided with sufficient means of access to spaces in and forward of the cargo area, to enable their required inspection and measurement. However, with the first of these vessels approaching
20 years in age, some access equipment, such as vertical ladders, has become unsafe due to, for example, corrosive environments, restricting access for surveys and increasing safety risks for crew.
In cases where these safety hazards apply, DNV has supported shipowners in carrying out scheduled inspections using unmanned drones. Equipped with highdefinition cameras, drones can access hardto-reach areas and capture detailed images in real-time. This technology eliminates the need for staging and rafting, reducing survey preparation time and minimizing risks to surveyors and crew.
The use of drones for survey purposes is still in its early phases and regulations are
being developed by IACS members, Flag administrations and other key stakeholders to ensure a safe framework for their use for inspections and required thickness measurements. Nonetheless progress is being made and improved safety levels from drones would be welcome across the industry.
On a more everyday basis, it is critical that the safety and efficiency of bulker operations are maintained through safe and reliable loading procedures. Proper loading not only prevents structural damage to the vessel but also ensures the stability and safety of the cargo during transit. Bulk carriers, with their large, single-deck cargo holds and wide hatches, require meticulous planning to distribute weight evenly and avoid excessive stresses on the hull and tank top. This is particularly important for special project cargoes or heavy break bulk such as steel coils, which can exert significant localized loads on the structure.
DNV has seen a growing number of requests for bulk carriers to carry oversized and heavy cargoes on deck, such as wind turbine blades and automotive vehicles. To meet this demand, we recently launched the “Deck Cargo” Class Notation, which aims to cover the regulatory requirements pertaining to vessels intending to carry deck cargo. This notation includes requirements for strengthening of the deck and hatch covers, as well as stability and navigational considerations which can ensure a safe and reliable voyage while transporting cargo on deck.
To improve loading procedures, DNV also recently launched its Steel Load Planner application. This improves the loading process for steel coils by offering a streamlined, self-service application that enables instant confirmation of rule compliance for proposed loading plans. The application also helps ship operators optimize cargo intake, reduce emissions per tonne-mile, and enhance safety by providing reliable information on the permissible load and optimal stowage patterns.
Along with other initiatives, DNV utilizes services and tools like these to support the safe and efficient transport of bulk cargoes, contributing to the overall reliability and sustainability of maritime operations.
This is a period of great transformation in the maritime industry. Driven by the increasingly urgent need to reduce emissions, stakeholders across shipping are making moves to improve the efficiency of vessels, while also making longer-term plans for the implementation of low- and zero-carbon fuels. This is leading to the evolution of existing marine technologies, supported by the rapid growth of digital systems and tools across the supply chain.
As the maritime industry strives to reduce its carbon footprint, DNV is at the forefront of supporting safe and sustainable decarbonization efforts. One of the key initiatives is the development of fuel guidelines for alternative fuels such as hydrogen, ammonia, and biofuels, which may be applied in greater volumes across the bulker fleet in the years ahead. These guidelines provide comprehensive information on the safe handling, storage, and usage of green fuels, helping shipowners transition to more sustainable energy sources.
Before these fuels become available at scale, energy efficiency can help bulker owners achieve short-term emissions reductions. Several energy efficiency options are already being applied to bulkers, with this set to become more common during the upcoming wave of newbuilds. These include design improvements, operational efficiencies and an array of energy-saving devices, such as shaft generators and variable-frequency drives.
The high availability of deck space on bigger, gearless bulkers such as Kamsarmaxes and Capesizes, and the long voyages on open seas that these vessels tend to take, means that wind-assisted propulsion systems (WAPS) are an increasingly attractive decarbonization measure for bulker owners. DNV is pioneering the adoption of WAPS
technologies by providing technical standards and relevant services, helping clients to navigate the complexities of WAPS installation.
For all energy efficiency measures, it is important that shipowners are aware of how much greenhouse gas reductions can be driven by their adoption and what kind of return on investment can be obtained. DNV helps shipowners to make these decisions by carrying out verification procedures on different technologies, comparing their effectiveness to a business-as-usual scenarios. Armed with this information, bulker owners can adopt these technologies with more certainty, helping to create long-term decarbonization strategies for their fleets.
With over 160 years of experience as a leading maritime classification society, DNV is constantly looking for ways to maintain and improve the safety of shipping. It works closely with its partners throughout the industry, and beyond, to stay on top of regulatory developments, support with technological evolution, and come up with innovative solutions.
This extends to a range of other services, including emergency response, port state control assistance, and compliance with a complex and changing regulatory environment.
As the maritime industry continues to evolve, DNV remains committed to advancing safety, efficiency, and sustainability.
By leveraging cutting-edge technologies and providing expert guidance, DNV supports bulk vessels and their crews in navigating the challenges of modern maritime operations.
Maintaining a dry bulk vessel is a continuous commitment requiring diligence, expertise, and a proactive approach, writes Hong He, Fleet Manager, ShiELD Services. It’s about striking the right
balance between preventative maintenance and timely repairs to ensure both the vessel’s longevity and the safety of its crew. At ShiELD Services, we prioritize structural integrity, optimize machinery performance,
enforce thorough safety protocols, and adhere to evolving regulations. Our comprehensive approach safeguards operational efficiency and ensures seamless cargo flow across global trade routes,
leveraging our expertise as technical managers of dry bulk vessels.
With downtime costing hundreds of thousands of dollars per day, staying ahead of maintenance is crucial. In this article, we bring you our key strategies to keep your vessel in peak condition, focusing on maintenance, safety, and repairs.
Machinery maintenance: The v lifeline of a vessel
A vessel is only as reliable as its main engine, generators, and critical auxiliary systems. Many breakdowns result from poor lubrication management or neglected wear and tear on fuel injectors. ConditionBased Monitoring (CBM) has transformed maintenance strategies, allowing us to track performance trends and detect anomalies before they escalate into critical failures. Planned maintenance goes beyond mere schedule adherence: it involves interpreting data, understanding operational patterns, and recognizing when a minor adjustment today can prevent a major breakdown tomorrow. By integrating data driven analysis with skilled expertise, we ensure that the operational status of the machinery remain at the forefront, minimizing downtime and maximizing operational efficiency. Safety and compliance: the human v element
No discussion on maintenance is complete without addressing safety. Advanced machinery alone cannot ensure safe operations but only a well-trained and safety-conscious crew can. Regular drills, continuous education, and disciplined to safety protocols ensure that the crew is well-prepared to handle both routine and emergency situations effectively. By fostering a proactive safety culture, we develop operational resilience and minimize risks at sea. Ultimately, a strong safety culture is both about compliance and building a mindset where vigilance, preparedness, and responsibility become second nature, ensuring the wellbeing of both crew and vessel.
Structural integrity: beyond v inspection to investigation
Among many, corrosion poses a silent threat to dry bulk vessels. Cargo holds endure wear from abrasive materials like coal and iron ore, while
ballast tanks are equally vulnerable. Routine inspections are vital, but proactive maintenance employs predictive techniques such as ultrasound testing and controlled dehumidification in ballast spaces. While high-quality coatings may seem costly upfront, they prevent far more expensive steel renewals in the long run. ShiELD Services’ comprehensive suite of technical management and operational support services is designed to mitigate such cascading failures.
Lack of attention to minor issues can quickly escalate into major problems. For example, consider a minor leak in a ballast tank’s piping system. If left unchecked, this leak can accelerate to corrosion within the tank due to increased exposure to seawater. Initially, this might only require a small patch repair. However, as the corrosion progresses, it weakens the tank’s structure, potentially leading to more significant leaks or even structural failure.
Worse, this can trigger cascading problems. The increased corrosion can contaminate the ballast water, affecting the vessel’s stability and trim. This, in turn, can strain the main propulsion system, leading to increased fuel consumption. Ultimately, addressing the accumulated damage will require extensive steel work, tank cleaning, and pipe replacements, resulting in significantly higher repair costs and extended downtime compared to the cost of a simple initial repair.
Prolonged downtime results in lost business and revenue and can create a negative ripple effect throughout the organization, causing delivery delays, impacting customer satisfaction, and
damaging your business reputation. At ShiELD Services, we pay prior attention to identifying potential risks before they manifest. Our commitment to safeguarding vessel performance, ensuring operational continuity, and securing the safety of every voyage is reflected in the success of our clients.
Maintaining a dry bulk vessel isn’t about reacting to problems, it’s about preventing them. The best-managed ships operate with seamless relationship between the technical team and crew, where data driven understandings guide decisions while maintenance actions prioritize long term performance.
At the end of the day, a ship is more than just steel and machinery, it’s a responsibility. The sea is relentless, but a well-managed vessel, backed by a proactive technical team at ShiELD Services, can withstand its challenges and ensure the continuous flow of operations supporting the global trade.
The path to safer and more resilient dry bulk logistics is paved with proactive measures, collective effort, and sustained dedication. By embracing early interventions and strict safety standards, the industry can minimize incidents, prevent costly detentions, and build a sustainable and reliable future. Together, with partners like ShiELD Logistics, we can promote industry standards for safety, reliability, and success in the dry bulk sector, leveraging our expertise in vessel management.
Shi.E.L.D. Services is a logistics management consulting firm specializing in dry bulk shipping. The company helps commodity traders, bulk shipping companies, and port operators streamline supply chains, reduce operating costs, and maximize profitability. With roots in Coeclerici, one of the industry’s leading players, ShiELD has built a reputation for excellence, reliability, and efficiency in maritime logistics and shipping.
As a trusted partner in bulk carrier and transshipment operations, ShiELD ensures continuity in the logistics chain, even in the most challenging environments. Its commitment to technical expertise, operational efficiency, and crew welfare cements its status as a leader in the industry.
Shi.E.L.D. Services is not just a ship manager, it is the silent force that keeps the logistics chain moving, ensuring that cargoes reach their destination safely, efficiently, and on time.
Dry bulk operations are undergoing significant change as the industry comes to terms with new realities.
Previously, safety in loading operations focused on compliance with a handful of basic regulations. Business operations remained mostly fixed. Cyber security felt lightyears away, like something from a science fiction TV show. And sustainability played a minor role in operational considerations.
In the ever-evolving bulk operations environment of today, data visibility, smart cargo operations, emission compliance and cyber security are prominently in focus as competing number one priorities, alongside important new safety considerations.
With higher safety requirements for loading operations in place, premier ship software suppliers have also re-engineered their solutions to go far beyond basic safety functionalities. The complexity of loading operations and the time-consuming processes in planning them necessitate solutions that make loading and sailing safer, smarter, smoother and more cybersecure.
Loading computers, such as Kaleris MACS3 for example, are premier software tools that focus on the safety of crew and ship during dry bulk operations. While these solutions span all kinds of dry bulk and container vessels, there are also versions of loading computer software in MACS3 that are specially designed for bulk carriers and their unique needs during loading and sailing.
The ideal loading computer for bulk carriers will include various modules to cover a variety of safety aspects for the vessel and crew:
Basic vessel safety checks the v stability and strength of the vessel during loading operations according to the stability booklet issued by the classification society to ensure compliance.
A safe loading sequence planning v module, such as Loadman in MACS3, automates cargo distribution and loading/unloading sequences according to the BLU Code. In the past, this task was done manually and was exceedingly time-consuming for the loading officer. Technology reduces the planning time to a matter of minutes and makes the pre-planning of loading sequences to balance the vessel during loading much safer, smarter and more flexible. Bulk carrier operators save money by optimizing cargo
distribution and save time by automating a formerly time-consuming manual planning task. They also receive a higher quality loading plan that promotes greater levels of safety. Load limits safety modules like the v MACS3 Bulklim ensure that load limits set by classification societies in the ship’s stability booklet are not exceeded. It includes an automated safety check of maximum load per hold, maximum load of two adjacent holds and still water bending moments per hold. This helps the crew confirm all holds are in a safe state during loading and sailing.
Flooded condition safety modules v like MACS3 Bulkstrength calculate the strength of a vessel according to IACS UR S17 when holds are flooded in an emergency situation. This includes a safety check of longitudinal strength in flooded conditions and a safety check of strength limit value in the assumed damaged hold. This module helps the crew to keep an overview of the ship’s condition in emergency situations and make informed decisions regarding their own and the ship’s safety. To ensure safety in dangerous v
goods handling, the crew must have an overview of their special cargo in compliance with the latest amendment of IMSBC, with integrated safety checks on IMDG, the vessel’s individual Document of Compliance Dangerous Goods, Document of Compliance Solid Bulk Cargoes, Company Rules and EMS. Multiple functions like chemical datasheet, checklist, segregation, compatibility and conflict handling make it easy to keep an overview on the potential threats on safety in the cargo on board of the ship.
Special safety for grain cargo, if the v bulk cargo is grain, the solution should have a special grain module that checks the compliance with the grain stability rule of SOLAS 74, the grain stability calculation forms in the US and compliance with grain stability of special port regulations.
Special safety for steel coil cargo v through a module that checks for ship-specific limits for steel coil loading. This module helps to plan a flexible loading of steel coils of different weights and diameters as well as plan the automated loading of
a complete hold with steel coils from a load list. It also gives clear warnings in graphical planning view and condition check-in case of exceedance. In addition, it provides an automated connection of the imported load list with the graphical steel coil planner.
All modules working together provide a unique and high level of safety during loading operations and in emergencies for bulk carriers, going beyond pure regulatory requirements and helping the crew focus
on safety and efficiency at the same time. All MACS3 software is IACS UR E27 cyber security compliant regarding interfaces, operating system and incident recovery strategy.
A solution like this for modern dry bulk operations helps ship crews provide a safe loading operation environment for themselves and the ship while also saving time with automated calculations. Dry bulk ship operators can use it to reduce operational costs by minimizing unnecessary consumption of ballast water
and simultaneously maximizing cargo capacity by weight or volume in loading and unloading sequences simulations. Beyond the operational safety aspects in the loading computer software, Kaleris also offers MACS3 Connected, a cloud version of loading computer data for bulk carrier operators that helps to share visibility on cargo and ship data between different stakeholders by mirroring the actual onboard situation on shore. As operators focus on sustainability initiatives, fleet performance solution Bluetracker provides special modules for dry bulk operations with calculation of total CO2 emission for each parcel of cargo to support emission compliance activities and regulatory reporting.
Kaleris carrier and vessel solutions have served the market for more than 40 years.
COSCO Bulk and China Shenhua Energy are two examples of bulk carrier operators that rely on Kaleris software to enhance the safety and efficiency of their fleets. The German Bulk Carrier Operator Orion Bulk GmbH also recently chose to standardize and retrofit its whole sailing fleet with the MACS3 loading computer.
A clean cargo hold is essential for bulk carriers, but ensuring cleanliness comes with significant risks. For decades, seafarers have faced the challenges of removing stubborn residues in hazardous environments — scaling great heights and enduring chemical exposure while being under pressure during discharging operations. The industry has long accepted these dangers as part of the job, but with modern advancements in technology, there also is a safer way forward: CLIIN Robotics from Denmark has spent over eight years developing a cargo hold robot that addresses the industry’s greatest pain points. This robotic cleaning solution is transforming the process by minimizing risks while improving both efficiency and cleaning standards.
ADDRESSING THE SAFETY CHALLENGES IN CARGO HOLD CLEANING
Cargo hold cleaning is more than just a routine task — it is a crucial aspect of vessel maintenance that directly impacts safety, compliance and operational efficiency. However, traditional cleaning methods introduce numerous hazards, from concerns in worker safety to the necessity of thoroughly cleaned cargo holds.
WORKER SAFETY CONCERNS IN CARGO HOLD CLEANING
Cargo hold cleaning has traditionally posed significant risks to seafarers, requiring them to work at dangerous heights, handle hazardous chemicals and endure physically demanding conditions.
Working at heights within large, cavernous cargo holds increases the risk of falls, especially when the surfaces are wet, slippery or covered in residues. In many cases, personnel must navigate ladders, ropes or scaffolding, where a single misstep can result in severe injuries or fatalities.
CLIIN Robotics’ system significantly reduces the need for working at heights, as the robot can be operated from ground level, often from a seated position, enhancing worker comfort and minimizing physical strain. From this vantage point, it can reach nearly the entire cargo hold. It performs exceptionally well on large, even surfaces like the Front Corrugated Bulkhead and the hopper, where cleaning is possible even during rough weather. Pipes and inner corrugations are also manageable, thanks to its adjustable highpressure tools. Topside tanks with angles
Wet cleaning of coal.
of up to 60° are effectively cleaned and even frames — both between and behind — are efficiently handled due to a specialized spray pattern. However, certain areas like access ways, stairs and hatch coamings still require traditional cleaning using high-pressure lances, also provided by CLIIN Robotics. Handling chemicals for cleaning purposes represents another layer of risk.
Even with protective equipment, accidental splashes or spills can lead to chemical burns or eye injuries. When combined with the physical strain of scrubbing or pressure washing, prolonged chemical exposure can exacerbate fatigue and heighten the likelihood of accidents.
CLIIN Robotics’ solutions eliminate the hazards associated with chemical use by relying solely on fresh water. The CHR
optimizes both water consumption and cleaning time. Depending on the cargo hold size, it uses only 40 to 70 metric tonnes of fresh water, compared to over 200 metric tonnes with conventional methods — reducing sludge and minimizing disposal costs. For instance, a Handysize cargo hold requires three to six hours and eight to ten tonnes of water, while a Capesize cargo hold needs eight to twelve hours and 12–16 tonnes. This efficient approach reduces environmental impact, speeds up turnaround times and improves operational efficiency.
Beyond worker safety, ensuring a cargo hold is properly cleaned is vital to vessel integrity and operational efficiency. Certain cargo residues, such as coal dust and oily substances, present serious fire hazards. When disturbed during cleaning, these residues can become airborne, creating an explosive dust environment. Heat, friction or improper cleaning techniques can lead to combustion, posing a severe risk to both crew and vessel safety.
Aggressive scrubbing or chemical-based cleaning methods can inadvertently damage the coatings or the cargo hold surfaces, leading to corrosion, contamination and costly repairs. By utilizing only high-pressure water without chemicals, robotic cleaning solutions effectively remove hazardous residues without introducing fire risks or structural damage. The CLIIN Robotics system operates at
200 bar, ensuring efficient cleaning with minimal risk of harm. For stubborn residues, the water can be heated up to 90°, providing enhanced cleaning power without compromising surface integrity.
For perhaps the most challenging of residues — cement — CLIIN Robotics offers an air-driven brush tool designed to remove cement without damaging the coating. This cleaning process involves two steps: first, dry cleaning with the brush tool, followed by a high-pressure water wash to ensure complete removal of the cement. This results in a spotless finish and the longevity of its surfaces.ultimately reducing maintenance costs and enhancing operational reliability.
Although the robot is an efficient cleaning tool, it is exactly that — a tool — and the need for human operation is still necessary. A human operator is crucial to oversee the entire process and ensure
spotless cleaning results.
The adoption of robotic solutions in cargo hold cleaning marks a significant step forward in improving safety, efficiency and environmental sustainability in the dry bulk industry. By addressing key safety challenges — limiting the need for manual labour, reducing exposure to hazardous substances, minimizing fire risks and preventing structural damage – these technologies provide a reliable and effective alternative to traditional cleaning methods.
Investing in these advanced systems is not just about improving cleaning processes; it is a proactive approach to safeguarding crew, vessels and the environment in an increasingly demanding maritime industry.
The maritime industry must decarbonize faster than ever before, and while the path is challenging, it is undeniably exciting, writes John Cooper, CEO, BAR Technologies.
At BAR Technologies, we believe that wind is the only reliable energy source available to the maritime sector that does not compete with other industries by utilizing wind as a fuel and capturing its full potential. We offer shipowners and managers an effective way to reduce fuel consumption and lower emissions, thereby enhancing long-term resilience against the volatility of traditional fuel markets.
Our revolutionary WindWings® system marks a major advancement in windassisted propulsion, particularly for bulkers, tankers and general cargo vessels. Developed using a patented three-element rigid wing inspired by aerospace engineering, WindWings® generates 2.5 times the thrust of a conventional singleelement wing. This aerodynamic efficiency translates into substantial fuel savings and a significantly reduced environmental footprint. In today’s highly competitive shipping industry, the ability to cut emissions while boosting overall vessel efficiency is crucial. To accommodate different vessel types and operational needs, WindWings® are available in three sizes: 37.5m, 24m, and 20m.
In August 2023, we marked a historic moment in commercial shipping through a partnership with Cargill. Mitsubishi Corporation’s Pyxis Ocean, chartered by Cargill, became the first vessel to be retrofitted with two WindWings®, each measuring up to 37.5 metres in height. Fitted directly to the ship’s deck, these innovative sails harness the power of the
wind to assist propulsion. Jan Dieleman, President of Cargill Ocean Transportation, summarized the significance of the project: “The maritime industry is on a journey to decarbonize; it is not an easy one, but it is an exciting one. At Cargill, we have a responsibility to pioneer decarbonizing solutions across all our supply chains to meet our customer’s needs and the needs of the planet. As an industry leader, in partnership with visionary shipowner Mitsubishi Corporation, we are not afraid to invest, take risks and be transparent with our learnings to help our partners in the maritime transition to a more sustainable future.”
This is particularly relevant given that 55% of the world’s bulker fleets are up to nine years old. In May 2024, DNV Maritime validated the performance of our WindWings® system. An interim DNV report revealed that, under favourable conditions, the two WindWings® installed on the MV Pyxis Ocean reduced the main engine’s energy consumption by an impressive 32% per nautical mile. These promising results are now informing plans for scaling up and wider adoption across the industry.
At BAR Technologies, we pride ourselves on a rigorous and proven methodology for integrating WindWings®, whether they are being retrofitted onto existing vessels or incorporated into newbuilds. Our approach begins with a comprehensive feasibility study that includes an assessment of the vessel’s general arrangement to best position our WindWings®, a detailed performance analysis tailored to the specific vessel, its routes, and its operational profile. Once
the potential is established, we document a tailored business case
Working closely with all project stakeholders, we finalize the scope and objectives so that every aspect of the project is clearly defined and agreed upon. With these decisions in place, the WindWings® system moves into production, marking the commencement of the next phase.
Once production is under way, we will proceed with the vessel integration and class approval process — a standard formality to validate what has already been rigorously designed and approved. WindWings® fully comply with all necessary regulatory and safety standards set by various flag states and classification societies. In parallel, foundation reinforcement prefabrication will commence, ensuring the vessel is seamlessly prepared to accommodate the system with minimal disruption.
After these preparatory measures, we conduct a factory acceptance test, followed by the final delivery of the WindWings® units. With the equipment delivered, the installation phase begins. The WindWings® are installed on the vessel with precision, and comprehensive sea trials are performed to validate the system’s performance and to ensure that the anticipated fuel savings and emission reductions are achieved. Finally, the system is maintained through regular servicing and maintenance at agreed intervals, ensuring optimal performance over its lifespan.
This step-by-step methodology, from the initial feasibility study through ongoing maintenance, is at the heart of our commitment to delivering state-of-the-art
wind propulsion solutions that not only meet but exceed the expectations of the maritime industry. Our rigorous, collaborative, and meticulously executed process is what drives sustainable change and supports the decarbonization journey for our clients worldwide.
Safety is central to our mission. WindWings® has been developed to meet the highest safety standards and has received DNV Design Type Approval, with further approvals in the pipeline. Designed for a 25-year operational life, the system features an emergency fail-safe behaviour that requires zero power to operate, ensuring safe configurations under all conditions. The design accommodates full green water loading whether the system is upright or folded and incorporates complete redundancy in the folding mechanism.
The benefits of integrating WindWings® into vessel operations extend beyond immediate fuel savings. Enhanced efficiency and reduced emissions translate into a lower total cost of operation over the vessel’s lifecycle. Moreover, the space optimization achieved by our design means that retrofitting existing vessels can be accomplished without significant disruption to deck operations. By harnessing advanced wind propulsion, our clients can future proof their fleets,
ensuring compliance with increasingly stringent environmental regulations and positioning themselves at the forefront of the industry’s sustainability drive.
The strides we are making with our WindWings® system exemplify the potential of wind-assisted propulsion to revolutionize the maritime sector. Our collaboration with high-profile partners, combined with rigorous validation from class, underscores our commitment to driving sustainable change. We are dedicated to enabling shipowners and managers to achieve their decarbonization goals by enhancing operational performance.
The journey toward a greener future in dry bulk shipping is well under way, and I am confident that the integration of WindWings® will play a pivotal role in that transformation. Our technology not only offers a path to lower fuel consumption and reduced emissions but also supports long-term operational resilience in an era marked by fuel price volatility and stringent environmental regulations.
Together, we can embrace the challenges of decarbonization and drive the transformation of the dry bulk shipping sector, one where wind propulsion is a fundamental pillar of sustainable maritime operations.
ESL Shipping achieved remarkable success in safety during the past year, notably reporting zero lost-time injuries throughout its entire operations. This achievement encompasses all vessels owned by the company and those participating in the Green Coaster Pool. While incidents did occur, they were all minor and effectively managed through First Aid or medical treatment.
The company’s commitment to safety is reflected in the significant reduction of the Total Recordable Incident Rate, which saw a decrease of 50%, bringing it down to 4.6. This statistic highlights the long-term work for safe working practices and the strong safety mindset of the whole personnel.
Furthermore, ESL Shipping’s performance in regulatory compliance was excellent, as the Port State Control deficiency ratio remained significantly lower than the average set by the Paris Memorandum of Understanding (MoU).
ESL Shipping will publish its 2024 Sustainability Report in April 2025.
ESL Shipping’s key focus of safety is on proactive measures to continuously promote the development of safety culture. Leading indicators of this commitment include practices such as management of change, safety walks and structured safety procedures.
Management of change process is emphasized as the company expands its cargo portfolio within the handy fleet. This proactive approach is crucial for ensuring the safety of its crew, ships and the overall quality of its services. Prior to loading new cargo types, accurate risk assessments are conducted, allowing the company to identify and mitigate potential hazards efficiently. Additionally, ESL Shipping prioritize communication among all parties involved in the process to manage changes and uphold high safety standards across our operations.
ESL Shipping is a carrier of dry bulk cargoes in the Baltic region. ESL Shipping’s competitive edge is based on its ability to responsibly secure product and raw material transportation for industries and energy production all year around, even in difficult weather conditions. The shipping company loads and unloads large ocean liners at sea as a special service. ESL Shipping Ltd has been in business for over 75 years and is a subsidiary of Aspo Plc. The combined fleet of ESL Shipping and AtoB@C Shipping consists of over 40 vessels with cargo capacity ranging from 4,000 to 25,000dwt.
Safety walks were initiated in 2023. This involves the management team actively participating in onboard safety walks to bolster the understanding of safe working practices throughout the organization. Safety reports, risk assessments, inspections, safety meetings and master’s reviews will be documented and accessible to involved parties in advanced electronic system, IRIS. This platform facilitates the monitoring of action implementation, ensuring transparency and efficiency in ESL Shipping’s safety protocols.
One of the main causes for concern in the shipping industry is the costly damage sea water can bring to a ship’s cargo, (and consequently, to the vessel’s safety) often resulting in high-cost insurance claims for shipping companies. To avoid this, hatch covers must be inspected and maintained regularly to identify the leaks that allow this damaging sea water into the cargo, and to ensure the integrity and safety of the hold. Many methods have been tried and tested to achieve this.
First, a simple but thorough visual inspection relies just on the use of a torch to assess the hold seal for rust, damage or residue which may indicate a leak. Whilst quick and easy, with no limitation to the frequency of inspection, often deterioration is invisible to the naked eye, and so the accuracy of this method is restricted. This is sometimes used in conjunction with chalk testing, in which chalk powder is applied to the gasket, highlighting potential leaks wherever the chalk has been rubbed away. Another method, water hose testing, involves spraying a jet of water at high pressure over the hatch cover. This has been widely used, but is also limited and somewhat impractical, simply because the hold must be empty so as not to cause any unnecessary damage to the cargo, which in itself involves significant time and man power. The vacuum box test, undoubtedly the most accurate mentioned so far, creates a vacuum in the hold by extracting all the air inside, measuring leaks by loss of vacuum. It is however, expensive and timeconsuming as it also requires advance planning for the hold to be empty. The final method, ultrasonic testing, is a quick and highly accurate leak detector test, and is also where Cygnus comes in!
CYGNUS’ PIN-POINT ACCURATE
ULTRASONIC LEAK DETECTION SYSTEM
Cygnus has applied its knowledge of the marine industry and ultrasonic expertise to a different angle and engineered a fast, effective, and economical solution — the Cygnus Hatch Sure ultrasonic hatch leak detector — for evaluating and testing cargo hatch covers and watertight seals to determine water leaks and weather tightness.
Unlike traditional methods, the Cygnus Hatch Sure ultrasonic leak detector cleverly conducts inspections with cargo in place, making it more time-efficient and cost-effective for testing bulk cargo carriers. Its capabilities are advanced, using
The Cygnus Hatch Sure ultrasonic leak detector cleverly conducts inspections with cargo in place.
a powerful and robust battery-powered transmitter containing 19 ultrasound emitters (40kHz), deliberately arranged to produce an omnidirectional sound field uniformly distributed throughout the space. The receiver simultaneously displays the sound energy level that passes through the area, enabling the user to identify the exact location of leakage accurately and quickly. Six selectable preset power levels also facilitate adjustment to any sized area, including confined spaces. This technology can give an indicator of the compression status of the seal. It can pinpoint cracks invisible to the naked eye whilst allowing operators flexibility beyond other methods. With Cygnus Hatch Sure, it is possible to regularly test, repair and test again to check the effectiveness of repairs, and over time build up a record history of the integrity of the hold. With this knowledge, repairs can be predicated and scheduled in advance, again increasing time efficiency. Furthermore, with such precision in identifying the location of the leak, repairs only need to be applied to a precise area, as opposed to using and paying for excess materials ‘just in case’. Crucially, a ship can be quickly inspected in port before it goes out to sea, to ensure it is sea and cargo-worthy.
The Cygnus Hatch Sure is ABS-typeapproved and accepted by P&I clubs; this environmentally friendly system is designed
for easy, quick, one-man operation without needing a team of inspection specialists. What’s more, the Cygnus Hatch Sure eliminates the need for time- and costconsuming preparations of arranging and loading water supply before host testing. Speed and convenience are central to its usability. Most notably, inspections can be conducted without clearing the space, ideal for sizeable storage facilities, where seal integrity is paramount, but shifting contents to permit inspection is impractical and inefficient. It is exceptionally lightweight and easy to transport with a rucksack-style carry case and neck and wrist straps for hands-free operation. With minimal training, an operator can test watertight doors, compartments, closing appliances and storage facilities for seal tightness and leakage effectively and efficiently.
Founded in Germany in 1982, Steelpaint GmbH specializes in developing and producing high-performance moisture cure coatings. Its range of advance corrosion protection systems for steel assets are used across a range of industrial sectors. This includes the maritime and port, heavy industry and renewable energy sectors.
The company services all kinds of vessels, including bulk carriers, container ships, MPVs, LNG tankers, ferries, ice breakers and passenger vessels.
The tried and tested moisture-cure (onecomponent) Stelpant line offers greater application and performance advantages over conventional two-component materials. “Our proprietary Stelcatec coating systems is a highly specialized, low VOC, isocyanate-free moisture cure Polyurethane coating that combines groundbreaking technology with the advantages of traditional moisture cure coatings,” says Frank Mueller, Sales Director at Steelpaint GmbH.
The Stelcatec range, which can not only be applied as topcoat, midcoat, and primer, is also available as a two-coat, or even single-coat system, certified and suitable for extreme C5-High environments. It cures exceptionally quickly and can be applied wet-on-wet under adverse weather conditions.
“Advantages include high dry film thickness tolerance and high compatibility with existing and old paint systems, generally,” adds Andreas Engert, Technical Director, Steelpaint GmbH.
According to Mueller, when it comes to surface preparation in the application process, “all major methods can be used,” including grit/shot blasting, slurry/vapour blasting, UHP/HP jetting, manual preparation with power tool, as well as ‘exotic’ methods like heat induction, icepellet blasting etc.
“Generally speaking, Stelpant/Stelcatec are highly surface tolerant. All major application methods can be used as well, including airless spraying, conventional airspray and application by brush and roller,” explains Mueller.
Moisture-Cure Polyurethane (MCPU) is at the core of Steelpaint’s product line. MCPU coatings cure upon exposure to atmospheric moisture, forming a durable protective layer. This technology offers advantages over traditional epoxy and polyurethane coatings, such as faster curing times and the ability to apply in a wider range of environmental conditions, especially at very high humidity levels of up to 98% and low-temperatures down to –5°C.
The Stelpant PU-Zinc product is a specialized primer containing 93% zinc content, providing exceptional long-term corrosion protection, and using the appropriate coating system offers compatibility to active cathodic protection measures. This one-component, moisturecured zinc-dust paint is surface-tolerant and can be applied in a wide range of temperatures and humidity levels, making it suitable for challenging environments.
The Stelcatec-L Series is a newly developed low VOC and the world’s first isocyanate-free moisture-cure polyurethane coatings system designed for extreme environments, offering rapid curing and allowing for wet-on-wet application under adverse weather conditions.
“The advantages over two-component coatings,” says Engert, “is that Steelpaint products are advanced one-component polyurethane coatings, offering durable protection for vessels and structures, ensuring long-term performance in harsh marine and extreme climatic conditions.”
Compared to conventional epoxy coatings, Steelpaint’s SP-MCPU coatings provide several distinct advantages: Ease of use and the fast-curing v properties, even under humidities up to 98% and on damp surfaces without dew-point restrictions, offer a much larger window for application and ensures that the project can be finished on schedule — sometimes even faster.
Enhanced durability and corrosion v Resistance: For instance, the SP-MCPU type coatings are engineered to withstand aggressive industrial environments, including exposure to saltwater, mechanical stress, and abrasive conditions. This resilience ensures long-term protection of assets such as sheet piles and port facilities, ships, offshore platforms, pipelines, and industrial facilities.
Simplified application process: The v one-component nature of SP-MCPU coatings eliminates the need for complex mixing procedures required by multi-component systems, streamlining the application process and reducing potential for errors. This feature is particularly beneficial in large-scale projects where efficiency and consistency are paramount as well as for lesser trained staff and on smaller scale touch-up/smart repair jobs. A general reduction in waste can also be mentioned in this case, since the one-component products do not have a limiting pot-life compared to the two-component products available in fixed pack sizes.
The coatings exhibit excellent v adhesion to a wide range of substrates, including steel, aluminium, galvanized surfaces, concrete and old paint. This versatility makes them suitable for diverse applications, from protecting maritime structures to industrial machinery and infrastructure components. The proven performance in v challenging conditions has demonstrated the reliability of the coating system as a robust and efficient solution for corrosion protection, outperforming traditional epoxy systems in durability, application
simplicity, and versatility across various industrial sectors.
The corrosion protection segment is a very conservative one and not quick to adopt new technologies. Mueller acknowledges that, “moisture cure materials are still widely regarded as a ‘new’ technology, even though they have been on the market for over 40 years. We introduced the Stelcatec system only 4 years ago, with increasing interest across a number of market sectors.” However, the company is continuously refining and developing the Stelpant and Stelcatec product lines.
The development of Stelcatec was also initiated in order to have a low VOC, zinc and isocyanate free material that will fulfil the harshest conceivable environmental laws that may be introduces in the next decades.
The company is also ISO 9001 and 14001 certified and, according to Mueller, “has annual internal audits and external service partners, that keep us up to date, and of course we are diligently following new releases of rules, regulations and laws applicable to our business sphere.”
Furthermore, the company has recently founded its Chinese daughter company and found a new business and distribution partner for India (Kaptel Overseas).
Steelpaint GmbH was established in 1982, building upon decades of expertise, as a specialized subsidiary focused on producing and exporting high-performance coatings.
Steelpaint has concentrated on developing one-component, moisture-cure polyurethane (MCPU). These products are designed to offer superior corrosion protection for various industrial and marine applications, including: Port and offshore facilities; v Sheet pilings; v External linings; v Cargo and storage tanks, including v ballast; Bridges; and v Ships. v
Since its foundation, Steelpaint GmbH has expanded and now serves a diverse range of industries. Its rich history reflects a steadfast dedication to innovation in protective coatings, evolving from its origins in the late 19th century to become a prominent provider of specialized solutions for hydraulic, industrial and marine applications.
Starting out on the German market Steelpaint has since expanded its business activities worldwide with subsidiaries and distribution partners in China, India, Singapore, Thailand and the United Kingdom.
Machinery downtime is a significant headache for every vessel operator, with unscheduled downtime being one of the most challenging issues, writes Stavros Zacharias, General Manager, Sales Development and Support for Parts and Field Services, Wärtsilä Marine.
Not only can it lead to costly repairs, but downtime often results in loss of asset income, loss of reputation, higher OPEX (e.g. higher insurance costs etc), as well as higher fuel consumption, higher emissions and CII deterioration. The latter could be particularly problematic when ship operators and owners have to compensate for delays in ship schedules by increasing vessel speed.
In particular, dry bulk vessels, which represent 43% of the global fleet’s total capacity, have limited opportunities for unscheduled stops and downtime. The timely delivery of cargo is imperative to operations, making it crucial for operators of dry bulk vessels to safeguard the reliability of their vessels.
Fuel quality, for example, has become a major problem for these vessels, endangering the key components of marine low-speed two-stroke diesel engines. Bad quality fuel can wear out injection components, leading to higher leakage rates, even uncontrolled injection or even main engine’s downtime. This can cause key engine parts to deteriorate rapidly, resulting in a tremendous increase in drifting or hardly manoeuvrable vessels.
To mitigate these issues, operators of dry bulk vessels should consider taking a variation of reactive and proactive approach to engine maintenance. The first part involves risk mitigation, in the event something happens, while the second part focuses on proactive maintenance.
It was against this backdrop that Wärtsilä launched its “Take Me Home” kits –specifically designed to help operators avoid cargo delays by drastically reducing downtime. The “Take Me Home” kits, which consist of OEM spare parts, include the most essential engine components affected by bad quality fuel. They are also available for a wide range of engine types. Kept on board, these kits help operators get the main engine’s fuel system back into operation quickly after an engine breakdown caused by bad quality bunkered fuel.
But having spare parts onboard is only effective if the crew are trained in how to properly operate and maintain the main engine. At Wärtsilä’s Land and Sea Academy (WLSA) — of which there are nine training centres located globally — crew can learn the essential skills needed to operate and maintain equipment from Wärtsilä and select partner OEMs. The courses delivered at WLSAs cover all aspects of equipment management generally — including maintenance, safety, availability, reliability and performance. Having both the spare parts on board and the crew trained is just one element, but what can operators do to ensure they are taking a more proactive approach to maintenance generally over the lifecycle of their vessels?
AND REMOTE OPERATIONAL SUPPORT
Before equipment breaks down, there are often signs that show something isn’t quite right. The problem is that these signs might not always be visible to the crew. Predictive maintenance services can analyse real-time data from sensors of an electronically controlled engine onboard a vessel. Advanced rule-based analytics, combined with a layer of artificial intelligence, can recognize when there is a potential issue and flag it up to a team of experts who can use their knowledge and experience to concretize the case at hand and alert the vessel operator or owner to anomalies and provide actionable advice and recommendations. Wärtsilä supports customers all over the world with its own digital predictive maintenance service which leverages Artificial Intelligence (AI) technology to identify potential failures before they occur, helping to improve asset efficiency and reduce operating costs.
Moreover, Wärtsilä’s Remote Operational Support (ROS) for 2-stroke
engines is targeted towards minimizing machinery downtime for dry bulk vessel operators. By providing real-time monitoring and expert guidance, ROS ensures optimal engine performance and swift troubleshooting, significantly reducing the risk of costly delays and enhancing operational efficiency.
LIFECYCLE UPGRADES
Looking longer-term, most dry bulk vessels have the potential to operate over two decades, if not longer. Lifecycle upgrades are essential to make sure that a vessel or fleet delivers maximum value throughout its lifecycle. Wärtsilä offers many lifecycle options to dry bulk vessel operators today — whether that’s engine upgrades, an engine conversion, adopting a hybrid solution or adding energy-saving technologies. Take the latter as one example — by optimizing the performance of a vessel’s existing propeller and combining this with Wärtsilä’s EnergoFlow (pre-swirl stator which creates an optimal inflow for the propeller) and EnergoProFin (energy saving propeller cap with fins that rotate together with the propeller) propulsion solutions could reduce a vessel’s emissions by between 6–10%. Looking longer term, operators can reduce emissions even further by converting their engines to an alternative fuel. For example, a conversion of an electronically controlled 2-stroke engine to LNG could reduce emissions by up to 20%. Additionally, converting to a more sustainable fuel could further reduce the ship’s emissions significantly.
Ultimately, applying these different measures ensure operators of dry bulk vessels better manage machinery downtime, whilst, at the same time, enhancing the safety, reliability, efficiency and sustainability of their operations over the lifetime of their vessels.
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The general cargo vessel Terneskjaer consumes 33% less fuel after a BERG Propulsion retrofit project.
Lighthouse Ship Management AS has steered one of its managed general cargo vessel coasters through a BERG Propulsion retrofit project which the Norwegian shortsea shipping service provider confirms has brought a 33% reduction in fuel costs.
The Torangsvåg-based fleet manager evaluated BERG’s options for optimizing energy use on board Terneskjaer, an 81m length 2,900dwt general cargo ship owned by Bio Feeder AS. The project sought to cut fuel costs and emissions, while adding a new competitive edge to a vessel built in 2008.
Following a consultative process, Lighthouse selected a BERG retrofit package enabling the conversion of Terneskjaer to higher efficiency dieselelectric propulsion, with BERG integrating a new gearbox and two permanent magnet motors with its MPC800 control technology. The solution provider also
optimized the blades on the ship’s existing BERG propeller to reflect changed operational needs, adding a nozzle to improve thrust — especially at lower speeds.
“A 33% reduction in fuel costs is highly significant and points to a secure future for a ship which has proved itself as a reliable performer in Norway’s demanding coastal sector for over 15 years,” said Lasse Øpstad, General Manager, Lighthouse Ship Management. “Managed prudently, ships built and maintained to Terneskjaer’s quality can comfortably surpass lower carbon requirements and compete effectively for years to come.” Lighthouse manages a wide range of ships for seven shipowners.
In securing lower nitrogen oxide emissions, the project was eligible to benefit from Norway’s NOx Fund, which allows owners tax breaks if they pay into a scheme to fund NOx reduction measures.
“There were several objectives for the
Under Lighthouse Ship Management, BERG’s energy optimization package adds a new competitive edge to the 2008-built vessel.
Terneskjaer project, including improved performance, greater operational flexibility, lower NOx, decarbonization and increased lifetime,” said Magnus Thorén, Sales Manager — Energy Efficiency, BERG Propulsion. “However, energy efficiency is critical in every respect. We consulted closely with Lighthouse Management to evaluate the upgrade options and we are delighted that the trust of one of Norway’s leading ship managers has been wholly vindicated.”
Berg Propulsion is a Swedish company providing a range of propulsion technologies, electrical integration and energy efficiency optimization solutions for commercial and naval vessels. It designs and manufactures controllable-pitch and fixed pitch propellers, azimuth thrusters and transverse thrusters, as well as vessel control and manoeuvring systems. Berg Propulsion is recognized as an innovative company that positions itself in the technical forefront of a changing marine industry, by developing solutions that are designed for high quality, performance and reliability.
Berg Propulsion has production facilities in Sweden, and direct sales & service offices in China, Singapore, Türkiye and United Arab Emirates. Furthermore, the company is supported by a global dealer & service network.
Replacing manual systems with datadriven process and structure can promote a smarter approach to safety and compliance, writes Gurinder Singh, Director of Technical Sales, ABS Wavesight.
A growing body of regulations and industry guidance emphasizes how to manage risk based on an understanding of condition. This means adopting a proactive approach that transitions from discrete tasks with a high and inbuilt risk of failure to robust, data-driven events.
For example, mooring line safety is not often top of mind but rather like other pieces of equipment, they gain attention when something goes wrong. The revision of SOLAS regulation II-1/3-8 and its associated guidelines by the IMO was undertaken to develop new guidelines for safe mooring operations for all ships in order to prevent unsafe and unhealthy work situations during mooring operations.
By collecting data on an event-to-event basis, including all daily inputs such as weather conditions and likely stress on components that may affect performance, it is possible to present the operator with a risk-based approach to condition, required maintenance and likely replacement timescales.
The industry continues to produce material guidance that helps vessel operators manage operational risks. One of the most important factors to consider is the mindset shift of how maintenance of such components is managed and how to get the correct information in front of the right people.
Being able to tailor this data can mean that vessel operators have a simpler path to compliance and a clearer view on condition and the need for intervention.
ABS Wavesight’s Nautical Systems™ software.
Effective compliance with IMO rules is just one example. Any rule change or revision that puts a significant compliance burden on a vessel operator needs a solution employing data management to be effective. Data can be used to support practical experience and drive better decision making.
There are limited software options that can manage this process. Our conversations with clients tend to focus on the need to move these problems towards data-driven outcomes that tie into existing fleet management software.
In our selected example, a voyage management system should be capable of capturing and reporting enough information to support compliance without increasing risk.
ABS Wavesight’s Nautical Systems™ software for example can combine the operational reporting features with the technical management need and use
workflow automation functionality to direct the required tasks to the responsible vessel team.
With maritime regulations moving progressively away from subjective and prescriptive standards and towards a probabilistic, risk-based approach, asset owners, as well as managers and crews have an opportunity to make better maintenance decisions.
The chances are that many routines of this type are still being managed on spreadsheets. In an era when software can be leveraged to support safety and compliance in day-to-day planning, data driven decision-making makes sense.
A condition-based approach means vessel owners and operators can take timely action based on verifiable data. Building process and structure means that technology becomes an enabler for safety and compliance, rather than a complication.
Low-maintenance cargo hold coatings for faster turnaround between cargo
The environment in which bulk carriers operate is often challenging and volatile, which means that ships must be equipped to withstand these testing conditions whilst maintaining their operational performance, writes Kazuaki Masuda, Corporate Officer, Technical Division at Nippon Paint Marine.
This need for protection and effective on-going maintenance is no less relevant for bulk carrier cargo holds. Across the diverse range of cargo that bulk carriers transport, from iron ore to coal and wood chip, as well as the toll that high impact loading operations can take, the hold itself
must be equipped to withstand contact from a variety of abrasive and potentially damaging materials to maximize the operational capacity of the cargo vessel. As a result, choosing the correct coating solution for a vessel’s unique operational profile is vital to ensuring highperformance protection and optimized operations.
Nippon Paint Marine has always focused its product innovation and development on deliver coatings that meet customers’ needs. Protective hold coatings are no exception. In 2024, Taiwanese dry bulk shipowner, Wisdom Marine Group,
consulted with Nippon Paint Marine to explore the latest coating solution that would provide high-performance protection from corrosion and mechanical damage for ten of the 150 vessels in their fleet.
Wisdom was keen to use a coating technology that would provide robust and long-term corrosion and abrasion resistance, to ensure that both goods in the cargo hold and the vessels themselves were protected during the bulk carriers’ day-to-day operations.
After a detailed consultation with the Nippon Paint Marine team, the shipowner
selected NEOGUARD TOUGHNESS as its preferred coating. This high-performance anticorrosive cargo hold coating is specifically designed to provide long term protection whilst operating in volatile marine environments. The heavy-duty system has been proven to provide significant protection to vessels’ cargo holds, whilst also securing significant cost savings by reducing the need for maintenance and lengthy down-time periods. The coating’s easy cleaning properties also allow for a quick and efficient turnaround between cargoes.
A further example of the efficacy of NEOGUARD TOUGHNESS was reported
in May 2024, when a leading logistics company’s 63,340dwt bulk carrier entered dry dock for routine maintenance.
During the vessel’s previous dry dock in December 2021, the customer’s main priority was to reduce maintenance during operations, NEOGUARD TOUGHNESS answered their need for such a cargo hold coating.
During its most recent dry-docking period, the ship owners arranged for a third-party inspection company to assess the condition of the vessel’s cargo hold. While the inspection report noted that the cargo hold had experienced secondary structural damages, the NEOGUARD
TOUGHNESS coating that had been applied to the damaged secondary structure was found to have remained intact, showcasing the robust durability of the cargo hold coating.
For over 140 years, Nippon Paint Marine has been committed to developing the latest in coating solutions designed specifically to support the evolving needs of our customers. In the time pressured drydocking environment, selecting a coating which is guaranteed to minimize application time, provide the highest standard of protection, and reduce maintenance, continues to be a key priority for Nippon Paint Marine customers.
Scanjet (an Alfa Laval brand) offers a range of advanced hold cleaning equipment designed specifically for bulk carriers. The primary models include the SC 30T and SC 90T2, both of which are engineered to provide efficient and economical cleaning solutions. These machines utilize sea water for washing and fresh water for rinsing, ensuring minimal corrosion and hindering salt contamination. The SC 30T features a fixed installed turbine with an integrated programmable drive unit, while the SC 90T2 operates similarly but with enhanced capabilities for larger vessels.
HOW IT WORKS AND BENEFITS
The Scanjet hold cleaning systems are designed to be both powerful and user-friendly. The cleaning process involves the use of foldable and/or vertically retractable installations, allowing for thorough cleaning even with closed hatches. This is particularly beneficial in adverse weather conditions where traditional cleaning methods would be impractical. The equipment is controlled from the deck, ensuring safety and ease of operation.
Portable cleaning machines are also provided by Scanjet if they are more suitable for the vessel.
BENEFITS TO THE CARGO/SHIP:
Quick change of cargo type: efficient hold v cleaning enables quick transitions between various cargo types, enhancing the vessel’s operational versatility.
Improved corrosion protection: by using v freshwater rinses, the equipment helps in reducing corrosion, thereby extending the
lifespan of the ship’s structure.
Enhanced safety: the cleaning operations v can be conducted with closed hatches, reducing the risk to the crew and ensuring compliance with safety regulations.
Economical cleaning: the efficient v cleaning process saves time and resources, making it a cost-effective solution for bulk carriers.
What sets Scanjet apart from other similar products is its commitment to customization and innovation. Each cleaning system is tailored to the specific requirements of the vessel, considering factors such as the internal steel structure, hatches, and general arrangements. This bespoke approach ensures optimal performance and customer satisfaction. Additionally, Scanjet’s patented magnetic transmission and permanent lubrication systems provide a maintenance-free, oil-free drive unit, further enhancing the reliability and efficiency of the equipment.
The installation of Scanjet hold cleaning equipment is a straightforward process, typically involving a preliminary study of the vessel’s drawings and discussions with the owner or shipyard. The equipment is designed for easy integration with existing systems, minimizing installation time and costs. Maintenance is equally simple, thanks to the permanent lubrication and magnetic transmission systems that eliminate the need for regular servicing.
PPG is responding to the fast-changing environment of the shipping industry, by significantly expanding its product portfolio with sustainably advantaged solutions, writes Ariana Psomas, Global Segment Director New Build and Dry Dock, PPG.
Our product diversification focuses heavily on meeting the growing customer demand for premium fouling control coating technologies that can help them minimize environmental impact and reach their sustainability targets.
The introduction of PPG SIGMAGLIDE® 2390 biocide-free fouling release coating reflects our focus on sustainably advantaged innovation. This silicone-based hull coating offers benefits which include up to 35% reduction in GHG emissions and up to 20% instant power savings compared to traditional antifoulings, while providing extended idle performance of up to 150 days.
Last year, we also launched PPG NEXEON™ 810 copper-free antifouling coating. Its unique formula can enable a total GHG emissions reduction of up to 25 percent compared to traditional antifouling coatings and supports resistance to idle times of up to 60 days with minimal speed loss. PPG Nexeon 810 antifouling features
photodegradable biocides that minimize environmental impact while maintaining superior performance and colour retention throughout the vessel’s service life.
In addition to coatings innovation, we have introduced electrostatic coating application in the shipping industry. This application technology significantly improves transfer efficiency compared to traditional airless spraying, which results in reduced overspray, minimized waste, and a cleaner working environment for applicators. The electrostatic process uses charged paint droplets that are attracted to the vessel surface with near-perfect precision, lowering environmental impact and VOC emissions.
PPG’s investment into promoting the use of electrostatic application aims to encourage a shift towards a more sustainable operation in shipyards, with less coating overspray and waste providing an improved working environment for applicators.
PPG’s successful experience with electrostatic application over the last 40 years in the automotive, aerospace and manufacturing industries has paved the way for the maritime sector adopting its use.
We are the first in the shipping industry to introduce this type of application, having developed coatings specifically suited for it.
By investing heavily in innovation and R&D of our coatings, we develop products that deliver superior performance while meeting stringent environmental standards. Our specialized coatings are engineered to last longer, reducing the need for frequent reapplication and maintenance, which translates to both environmental and economic benefits for PPG and our customers.
We have seen an increase in demand for our sustainably advantaged hull coatings, PPG Sigmaglide 2390 fouling release coating and PPG Nexeon 810 antifouling. Thanks to their unique formulations, these coatings are ideal for electrostatic application, and we’ve experienced real success with this advanced method, particularly in reducing environmental impact and improving efficiency for our customers.
The EDR Antwerp shipyard achieved a 40% reduction in overspray with the electrostatic application of PPG Sigmaglide 2390 fouling release coating. This was the second successful electrostatic application project we completed with EDR and was carried out on the underwater hull of the RoRo passenger vessel Stena Transporter from Stena Line. EDR’s commercial manager, Philippe Trouillard, said “Electrostatic application increases the weather window in which painting activities can take place, as well reducing overspray significantly. It’s impressive to see how the charged paint droplets are attracted to the vessel surface almost like a magnet. You only have to look at the dock floors at the end of the project to see how much paint has been saved from disappearing into the environment. Due to a cleaner operation, we have spent less time masking the vessel and covering the dock, saving valuable time and costs.”
Our 50th vessel using electrostatic application was carried out on the VLCC SIDR, a 336-metre oil tanker operated by Bahri Ship Management at the Asyad Drydock Company shipyard in Oman and used PPG Nexeon 810 antifouling. Ship Management President at Bahri Khalid Alhammad, said “A cornerstone of our environmental strategy is to reduce carbon emissions of our entire fleet and to achieve these objectives, we constantly adopt the latest technologies in hull coating that would help reduce vessel emissions. Combining that with a sustainable coating
First drydocking for COSCO Shipping with electrostatic application of PPG SIGMAGLIDE 2390.
application technique makes it an attractive combination to us.”
In addition, we have also recently announced the first PPG Sigmaglide fouling release coating drydocking for COSCO Shipping Energy Transportation Ltd, the largest tanker owner in China, using the electrostatic application. This was carried out on the Yuan Chun Hu, a 333-metre crude oil tanker owned by COSCO Shipping at the Liuhengdao shipyard in Zhoushan, China. PPG Sigmaglide 2390 coating was applied to the underwater hull,
while PPG Nexeon 810 solution was used on the boottop.
We are observing a significant shift among ship owners as they review their existing coatings in response to new environmental regulations, such as the Carbon Intensity Indicator (CII) and the Energy Efficiency Existing Ship Index (EEXI), as well as the broader drive towards achieving Net Zero in the shipping industry. These regulations and goals are having a pronounced impact on the demand for specific types of coating products.
We have noticed a notable rise in the demand for hull coatings that can effectively reduce power demand and emissions. Products like biocide-free Sigmaglide and copper-free Nexeon are particularly sought after for their ability to enhance vessel efficiency and contribute to emission reductions.
As ship owners aim to comply with CII and EEXI regulations, coatings that offer superior hydrodynamic performance and lower friction are becoming increasingly
popular. These coatings help in reducing fuel consumption and, consequently, greenhouse gas emissions, aligning with the regulatory requirements.
The stringent environmental regulations are driving ship owners to prioritize coatings that not only meet but exceed regulatory standards. This shift is evident in the growing preference for advanced coatings that support sustainability goals.
Beyond regulatory compliance, these coatings provide economic benefits by reducing fuel costs through improved efficiency. This dual advantage of regulatory adherence and cost savings is propelling the demand for innovative coating solutions.
Overall, the push towards Net Zero and the introduction of new environmental regulations are significantly influencing the marine coatings market. Ship owners are increasingly investing in coatings that offer both environmental and economic advantages, underscoring the critical role of advanced coatings in the future of sustainable shipping.
The key dynamics of the dry bulk carrier market – availability, flexibility and reliability — mean that uninterrupted operations are essential for these vessels to stay competitive, writes Vasileios Gkikas, ABS Director, Business Development, Global Bulk Carriers.
In addition to the fundamental principles of safe operations, effective maintenance and efficient troubleshooting are key to ensuring vessels can be operated without interruption.
Starting as early as the design stage, at ABS we review the specifications and qualify any new technologies to be applied. At the construction stage, we consider the wide range of designs, processes, material and equipment certifications, as well as detailed structural assessments that are fundamental across the full range of shipyards, including smaller facilities.
ABS’s enhanced survey scheme during vessel construction helps ensure a high level of quality assurance. Our expertise in specific domains like Shaft Alignment which can lead to the granting of the Enhanced Shaft Alignment notation to indicate a vessel that has undergone a more detailed and rigorous process, aiming to improve powertrain service life and minimize potential issues.
Once the vessel is on the water, our
global network of experienced surveyors continues to provide 24/7 support to owners for any issues they may encounter, ranging from a simple equipment malfunction to more serious incidents. ABS has also been working to study the implementation of advanced repair procedures that can be applied in situations where a repair site is inaccessible to our teams.
Operational support is enhanced using remote surveys which provide either a complementary means of inspection or an equivalent standalone solution where immediate attention is required, and physical attendance is not feasible. ABS is already working on several pilot projects for the use of drones going beyond closeup surveys to perform thickness measurements. ABS has also established a Condition Assessment Program for Bulk Carriers, which is already proving of interest to market stakeholders.
When it comes to specific technology employed onboard such as cranes, exhaust gas scrubbers or ballast water treatment, our certification scheme helps to ensure compliance.
For non-standard cargo loading (steel coils, containers, wind turbine blades on deck), ABS has developed review and approval methods and processes to promptly address these requests usually
with the need for swift approval.
With regard to Port State Control (PSC) inspections, ABS holds the leading position over the last couple of years in global PSC league table performance, mainly due to the establishment of a set of internal processes and procedures as well as programs and training that allow owners and operators to better prepare for inspections especially at some critical locations such as Australia, China, and North America.
Recognizing the specific importance of the Pilbara region in western Australia for the more than 400 capesize bulk carriers currently in its classed fleet, ABS has established a permanent survey station providing on the spot the support at the key dry bulk terminals of Port Hedland, Dampier and Walcott.
Last but not least, ABS’ digital ecosystem provides clients with comprehensive information concerning their fleet, including the latest regulatory and port state information. Users receive relevant alerts, can access rule and regulatory references and manage full control in their day-to-day operations with the ability to anticipate and plan surveys, issue customized checklists, including full access to vessels’ documentation and certificates online via a dedicated web portal.
A new deep water bulk berth has been opened at the Port of Liverpool which will give a major boost to the port’s cargo handling operations.
The first deep water bulk berth to be opened at the port in 40 years is located at Peel Ports Group’s Alexandra Complex, and represents an investment of £2 million by Peel Ports as part of its ongoing development of the Alexandra Complex.
The berth welcomed its inaugural vessel on Friday – the Andesborg – and will accommodate vessels up to Handymax sizes.
Combined with the existing N3 Alex berth, the new addition will increase the vessel handling capacity of both the Alexandra Complex and the Port of Liverpool as a whole.
The 534,000ft2 complex, where a £28 million state-of-the-art warehouse was also
recently developed, is designed to provide a full, efficient solution for customers’ bulk storage and handling requirements.
Phill Hall, Mersey Port Director, Peel Ports Group, said: “This is a significant moment for the Port of Liverpool. The addition of the new deep water bulk berth will not only allow us to accommodate larger vessels, it will also improve the port’s overall ability to manage bulk cargo, providing more efficient cargo operations and helping us to keep supply chains moving.
“Not only does this project show our dedication to investing in infrastructure, when combined with our modern storage facilities the new berth ensures we can handle a diverse range of commodities and support customers with their needs.”
Warehousing space is currently available at the Alexandra Dock Complex and
interested parties should contact Peel Ports for more information.
Peel Ports Group is the UK’s secondlargest port operator, owning and operating six of the UK’s most important ports (Liverpool, Heysham, Manchester Ship Canal, Medway (Sheerness/Chatham), Clydeport and Great Yarmouth). It also operates a container terminal in Dublin and owns BG Freight Line, which provides short sea container services between the UK, Ireland and mainland Europe and Peel Ports Logistics, one of the UK’s leading shipping and freight forwarders. Peel Ports handles approximately 70 million tonnes of cargo every year. Some 14% of the total UK major ports traffic flows through ports operated by the Group. Headquartered in Liverpool, it employs around 2,000 staff.
The maritime industry is on the cusp of a digital transformation that has already revolutionized other industries such as aviation, writes Kris Vedat, CTO SmartSea. As one of the oldest businesses in the world, it still relies on operational procedures that in some cases are over a century old. Whilst major liner hubs have heavily invested in automation and digital technologies, dry bulk terminals are less mature in their digital offering. It is therefore more important than ever to look at how the introduction of smart ports can help transform the dry bulk industry.
The dry bulk sector plays a critical role in the global shipping industry, responsible for transporting non-liquid bulk commodities like coal, grain, iron ore, and other raw materials. These goods are essential to industries like construction, energy, agriculture, and manufacturing. As one of the most important segments of the maritime transport sector, dry bulk shipping accounts for a substantial portion of global trade volume.
However, one of the main inefficiencies in dry bulk shipping stems from the isolated nature of port operations. Unlike container ports, where digital investments have optimized berthing and cargo handling, dry bulk terminals often only operate reactively. This is exacerbated by the fact that ports, shipowners, and cargo handlers frequently act as independent entities rather than as a connected supply chain.
Unlike the container industry, which benefits from Electronic Data Interchange for Administration, Commerce, and Transport (EDIFACT) messaging, the dry bulk sector lacks a unified system for communication between ports, terminals, and vessels. Digitally, ships don’t talk to ports at all which can cause huge delays and reports from vessels are not delivered in a standardized format, making it difficult for ports to integrate this data into their own systems.
Dry bulk cargo also presents unique challenges compared to container shipping. It includes a wide range of commodities such as grain, minerals, and ad hoc cargo, each with its own requirements. Unlike liner shipping, where cargo movements follow predictable schedules, dry bulk shipping often involves fluctuating demand and availability issues.
A smart port system powered by predictive analytics can help mitigate these
challenges. By analysing past shipping patterns, port congestion levels, and cargo availability, terminals can optimize berthing schedules and ensure seamless cargo movement. For instance, if a port knows in advance that tugs or pilot services will be delayed due to weather conditions, it can communicate this information to inbound vessels, allowing them to slow steam rather than waste fuel idling outside the port. This would not only improve efficiency but also help lower emissions. Such systems transform port operations from being reactive to proactive, enhancing efficiency across the entire supply chain.
How do we achieve this? Well, like many things, it’s all down to the quality of the data and this cannot be interpreted without proper standardization. Data standardization must become the foundation of smart port development, requiring collaboration among shipowners, regulators, terminal operators, technology providers and logistics operators.
However, there are many factors to consider. The global shipping industry operates across vastly different levels of technological maturity. While European and Asian ports have embraced digitalization, some terminals in less advanced countries like, for example, West Africa, have not. Implementing smart port solutions on a global scale requires factoring in these disparities. If the industry wants a fully interconnected supply chain, the solutions must be scalable and adaptable to varying levels of digital readiness.
Security is a growing concern as ports become more data-driven. The lack of a standard cybersecurity framework leaves many terminals exposed to cyber threats. As the industry moves forward, port operators must adopt robust security protocols and develop cybersecurity as a specialized discipline. There are also some countries which have not established cybersecurity frameworks for maritime operations at all, leaving its terminals open to cyber threats. Without a global standard, the digital transformation of the dry bulk sector remains fragmented and open to security risks.
So how best to proceed? Well, the journey towards fully optimized smart ports will not happen overnight. Data standardization, infrastructure investment, and industry-wide collaboration all require time and commitment. The return on investment will not be immediate, but the long-term benefits of greater efficiency, lower emissions, and a more resilient supply chain are undeniable.
As technology advances, improved satellite communications (such as Starlink and OneWeb) are making digital solutions more feasible, even in remote locations. This enables even traditionally underserved regions to participate in the smart port evolution. But in order to do this effectively the industry has to adapt. It is no longer the sole responsibility of the port authorities, or the ship owners or the legislators, it is in all our interests and the success will depend on the implementation of data collaboration.
Aviation provides a compelling example of successful data collaboration. Leading aviation technology provider, SITA, developed an aggregated platform enabling independent parties to communicate securely. As a result it helped achieve seamless data standardization in aviation, enabling passengers to check in luggage at any airport in the world and retrieve it at any destination, even after multiple airline transfers.
This type of collaboration is essential for smart ports to reach their full potential. Maritime logistics needs a similar system where shipping lines, ports, and regulators share data securely and transparently. This is the future of maritime operations.
SmartSea is backed by aviation technology leader SITA and is taking lessons learnt from the aviation industry and utilizing its technology to transform digitalization in maritime through our integrated platform, with the vision of unifying the sector and bringing everything together under one roof.
The move towards smart ports will inevitably lead to increased automation, shifting the skill sets required for terminal operations. Future ports will rely on AI-driven logistics, automated cargo
handling, and digital communication systems, requiring a workforce proficient in data analytics and cybersecurity. This brings its fair share of challenges, opportunities and threats in an industry which desperately needs to recruit the next generation of seafarers. This will require a whole new set of skills too.
The long-term benefit of smart ports will provide better co-ordination across the entire supply chain. With connected systems, all stakeholders, including port operators, shipping companies, and logistics providers, can share data and collaborate more effectively. This seamless communication leads to faster decision-making, fewer delays, and more efficient cargo operations.
Automation plays a significant role as well. Automated cranes and robotic systems are increasingly used to load and unload dry bulk cargo, which increases the speed and safety of operations. Additionally, automated trucks and drones can help transport cargo within the port, further reducing the need for manpower and minimizing potential errors.
Overall, smart ports represent a transformative force in dry bulk shipping, boosting efficiency, reducing costs, and
A concession has been officially signed between the Brazilian government and Cedro Participações for a new iron ore terminal to be built in the Port of Itaguaí. The terminal (ITG02), which will require estimated investment of $624 million, will cover a surface area of 250,000m². Once operational, it will have the capacity to handle up to 20 million tonnes annually, which will boost handling capacity at the port by a third.
Barry Cross
improving sustainability. As more ports adopt these technologies, the entire dry bulk shipping industry stands to gain.
In order to do this the dry bulk sector must move beyond the outdated mindset that port efficiency is solely the responsibility of terminal operators. Every stakeholder in the supply chain, from shipowners to cargo handlers, has a role to play in fostering digitalization. Competing against each other in siloed operations will no longer work. The industry’s shared goal is to move cargo efficiently and safely and the best way to achieve that requires agreement to work together from all sides collaboratively.
SmartSea believes that maritime logistics should follow the aviation industry’s lead in data standardization and interoperability. By working together to establish a unified digital foundation, the dry bulk sector can achieve the efficiency, and sustainability gains that smart ports can provide. This is not just a technological shift; it is an industry-wide transformation that demands commitment from all interested parties to ensure that dry bulk continues to adapt and innovate the varying supply chain demands of this incredibly volatile sector of the maritime industry.
The Argentinean Port of Barranqueras believes that the recent export of three containers filled with charcoal is a highly significant move. The three 20-tonne boxes went to the Italian cities of Sardinia and Naples, and to Valencia, in Spain.
According to local officials, the move represents a “paradigm shift” and justified the need for appropriate infrastructure to be available. The port has recently acquired a state-of-the-art container scanner, allowing it to reactivate exports and improve cargo consolidation. This technology will also be used to check cotton fibre shipments, further expanding the port’s logistics opportunities.
However, the need to bring forward dredging work in Barranqueras Creek has also been highlighted, if the port is to further benefit from international trade opportunities. The surrounding Chaco province is already a leader in exports, having registered growth of 30% growth in 2024. Italy is a key market, with imports of Chaco products worth almost $11 million.
The port also wants to attract more coal exports, which were previously in decline. This occurred because HGVs had to go to Sáenz Peña, unload their coal shipments, then bizarrely reload them for inspections. This process has been subsequently streamlined.
In reference to charcoal exports, the latest three shipments are a pilot project by the exporter, and represent considerable consolidation of batches. The intention is to do more of this, progressively increasing the volume of cargo sent to Europe.
Indeed, the port is deliberatively trying to attract even more small producers, whereas previously exports were restricted to just five companies. “Our challenge is to show that the port has the necessary equipment and logistics [in place] so that HGVs can arrive, unload, and load containers,” said the port. Barry Cross
The northern Chilean Port of Arica is to commence handling bulk minerals using rotainers. These will allow concessionaire Impala Terminals to eliminate traffic build ups within the heart of the port by making exclusive use of a new facility in the outer harbour.
To this end, construction work began in March 2025 on a new 11,117m2 dedicated, minerals handling warehouse, at an initial cost of $15 million. When it opens in early 2026, it will ensure increased environmental protection, since handling will no longer take place so close to the city centre.
At present, loading process makes use of a single, airtight conveyor belt system to fill tilting airtight containers. In future, such operations will shift to a brand new negative-pressure hermetically sealed warehouse. This will receive minerals, and then process prior to them being shifted to the dock for loading. This will cut out the need for HGVs to convey these shipments via city centre roads.
The majority of the minerals are inbound from the Bolivian cities of Cochabamba and La Paz. In future, they will enter the terminal via Route 11CH, located at kilometre 2 in the Port of Arica’s outer harbour.
In terms of new equipment, the port will acquire up to 420 rotainers, and has already purchased the necessary spreaders to handle these boxes.
Estimates suggest that the new rotainer-based system will allow Arica to handle a minimum of 200,000 tonnes annually, although the minimum guaranteed movement will be 140,000 tonnes. Nevertheless, the port expects to boost the total number of shipments because processes will be much faster.
At present, for example, all bulk carriers entering Arica have to dock at Berth 5, because the sealed conveyor system is located there. This creates some operational limitations, because that berth is prioritized for container handling, meaning bulk carriers are often forced to wait at anchor for up to a week before the berth is free.
This will no longer be the case once the new warehouse is opened, boosting flexibility, handling speed, and efficiency, as well as reducing overall costs. Crucially, it will also allow Arica to eliminate all mineral stockpiling at the port.
Arica is also hoping that its improved efficiency will also prompt some minerals exports to shift from ports in southern Peru to northern Chile. Barry Cross
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Situated at the heart of Denmark, the Port of Grenaa continues to solidify its role as a crucial gateway to and from the Baltic Sea. Serving as a strategic hub for industrial bulk sectors across Northern Europe, the port is making significant strides in infrastructure development, operational efficiency, and strategic partnerships. These initiatives are not only enhancing its capabilities but also reinforcing its commitment to innovation and sustainability.
As part of its long-term investment strategy, the Port of Grenaa is set to welcome the Mantsinen 300DEMG crane in April. This advanced piece of equipment is specifically designed to optimize bulk operations, facilitating the efficient handling
of key raw materials such as sand, gravel, stone, salt, wood pellets/- chips and gypsum. These materials are essential for construction projects and power plants in Northern Europe, making the port a critical logistics hub for the industries.
Additionally, the port is planning further expansions to its bulk handling infrastructure, with up to 12,000m2 of new bulk warehouses currently on the drawing board. As market demand continues to grow, these future facilities will ensure that
the port remains well-equipped to manage diverse cargo loads efficiently. This expansion underscores Grenaa’s commitment to maintaining its position as a leading port for bulk handling in the region.
Further reinforcing its competitive edge, the Port of Grenaa has established a strategic alliance through Kattegat Port Alliance, a partnership with the Port of Halland in Varberg and Halmstad. This collaboration aims to enhance maritime connectivity, streamline logistics, and create new business opportunities for port users. By working together, the alliance will foster economic growth and bolster the port’s status as a vital hub for international trade.
Moreover, the port continues to focus on sustainable development initiatives, including the enhancement of its existing methanol facility. This investment aligns with the broader industry shift towards greener energy solutions and showcases the port’s dedication to environmental responsibility. Collaborations with industry leaders, such as Stena Recycling, further highlight its commitment to innovation, sustainability, and operational excellence.
With ongoing investments in infrastructure, state-of-the-art equipment, and strategic partnerships, the Port of Grenaa is well-positioned to meet the evolving demands of the shipping and logistics industries. Its role as a key player in the Kattegat region will only grow stronger, ensuring long-term benefits for businesses, stakeholders, and the wider community.
Furthermore, the establishing of a large-scale CO2 storage HUB will have special focus the coming years, with the aim to be operational in 2028.
As the port looks to the future, it remains committed to embracing cutting-edge technologies, fostering sustainable practices, and strengthening its position as a premier maritime hub in Northern Europe.
Significant growth in cargo handling, new records in the handling of construction materials, minerals and containers, also Klaipėda taking almost a quarter of the market among Baltic country ports — this is how the year 2024 could be briefly described for the Port of Klaipėda. It ended the year with 35.5mt (million tonnes) of cargo handled, recording an 8% growth and a 39% market share among Baltic country ports.
“Klaipėda Port handles a diverse range of bulk commodities, including fertilizers, agricultural products, and construction materials,” says Algis Latakas, Director General of Klaip ė da State Seaport Authority.
“Despite the geopolitical challenges,” continues Latakas, “the Port of Klaipėda. has remained the first choice in the Baltic Countries. While surrounding ports are still looking for ways to overcome their difficulties, Klaipėda is showing steady growth. These results are due to the Port Authority’s steady investment in infrastructure, the companies’ determined decisions to modernise their equipment, and their persistence in working with their customers. Klaipėda Port’s cargo handling performance is not only a number, but also a symbol of a reliable and innovative partner.
“In 2024, the highest growth in the Port of Klaip ė da was in the handling of construction materials and minerals. The handling of these cargo almost doubled (99%) from 1,040,000 in 2023 to 2,068,000
tonnes in 2024. This growth is mainly driven by active road and rail construction. This is historically the highest-ever volume of handling operations in the Port of Klaipėda. The majority (93%) of the construction materials and minerals handled at the port last year were imported, with almost half of the imports (47%) coming from Scandinavian countries.”
Container cargo handling was the second largest contributor to tonnage growth last year, with 859,000 tonnes or 9% more than in 2023.
The third place for cargo handling, in terms of tonnage growth last year, was won by cargo group ro-ro — with 852,000 tonnes or 16% more than in 2023. This is the second best cargo handling result in
this segment in the Port of Klaipėda.
There was also a significant increase in the handling of timber and forestry products, with 244,000 tonnes or 49% more handled cargo. Last year, 189,000 tonnes of iron, steel and steel structures were handled, or 75% more than in 2023. Fertilizer handling grew by 201,000 tonnes or 13% — in 2024 1.76mt was handled.
The number of ships arriving at the port has also increased. Last year, the Port of Klaipėda received 5,478 of them. This is an increase of 132 or 2% compared to 2023. The number of passengers using the Port of Klaipėda last year was slightly more than 381 thousand — an increase of around 25,000 or 7%.
Some 98 ships (including ten modernization projects) have been
repaired in the Port of Klaipėda, and one hull has been built with partial fitting out.
Looking at last year’s cargo handling and dividing it into quarters, the second half of the year was more successful for Klaipėda Port. In both third and fourth quarters of the year, cargo handling exceeded 9mt tonnes.
Last year was the most successful year for the Port of Klaipėda compared to other Baltic country ports. Its market share grew by 3 percentage points, from 36% in 2023 to 39% last year.
The Port of Tallinn’s cargo handling in 2024 increased by 548,000 tonnes or 4%. In total, the Port of Tallinn handled 13.1mt of cargo in 2024.
The Port of Riga saw a drop in cargo handling of 732,000 tonnes, or 4%. In total, Riga handled 18.1mt of cargo. In Liepaja, cargo handling fell by 3% to a total of around 7mt last year, while in Ventspils it fell by 21% to 8.2mt. Combining the three Latvian ports, their handling consists of 33.3mt of cargo. This is 6% less than the cargo handling of the Port of Klaipėda alone.
“Klaipėda Port Authority continuously
“Bega”
invests in the port’s development to ensure it meets market demands and remains competitive ,” concludes Latakas. “However, the port’s success is also driven
by the dedicated efforts of private companies operating within it, which play a key role in retaining and serving their clients effective.”
Mirroring overall results of the Port of Klaip ė da (see article above), Klaip ė da Stevedoring Company “Bega” demonstrated growth dynamics as well, surpassing its cargo handling volumes from 2022 and 2023. The company’s cargo portfolio was dominated by agricultural products, primarily grain. Additionally, the past year saw the reintroduction and expansion of various cargo types, including mineral materials, raw materials for fertilizer production, bulk fertilizers (both imported and Lithuanian-produced exports), as well as edible oils, cement, liquid fertilizers, and other bulk and liquid commodities. The company also continued handling de-icing components, mixing them to produce the final product.
As part of its ongoing commitment to enhancing cargo handling, export, and import services, “Bega” continued to invest in operational improvements in 2024. One of the key developments was the launch of a new Terminal Management Center, which integrates all automated company terminals into a centralized control system. This advancement significantly enhances the efficiency of logistics and cargo operations, optimizing the reception, storage, and loading of agricultural and other bulk or liquid cargoes onto vessels.
With these investments, cargo handling processes across different terminals are now managed from a single hub, ensuring improved data sharing among logistics and cargo handling chains, strengthened monitoring and control of operations and equipment, and enhanced working conditions for terminal operators.
A notable innovation in 2024 was the introduction of inland waterway transportation for Lithuanian grain exports. For the first time, grain shipments
to “Bega’s” terminal were delivered not only by rail and road transport but also by river barges along the Nemunas River. “The utilization of inland waterways for grain transportation to the port marks a significant milestone. Having served agricultural producers and traders for many years, we recognized the demand for this alternative logistics route. Transporting export grain by barge from specific Lithuanian regions to the seaport terminals — and, in return, delivering
imported fertilizers or other essential agricultural goods — presents substantial logistical benefits. Furthermore, shifting cargo transport from roads to waterways can significantly reduce heavy truck traffic. If, as planned, the barges are pushed by electric towboats, this segment of the cargo journey will be nearly emission-free,” said Laimonas Rimkus, CEO of Klaipėda
Stevedoring Company “Bega.”
Since 2016, “Bega” has been implementing a Green Transportation Development Program, progressively converting its rail locomotive fleet from diesel-powered shunting locomotives to electric, robotic units. As a result, the majority of rail manoeuvres at its terminals are now conducted with zero emissions.
The programme is ongoing, with plans to further incorporate electricity and alternative fuels, such as green hydrogen, for railway transport and cargo handling equipment. With its continuous investment in modernization and sustainability, “Bega” remains at the forefront of efficient, eco-friendly cargo handling solutions in the Port of Klaipėda.
Mibau Stema, one of the largest suppliers of mineral construction materials in Europe, is now expanding its already significant engagement at the Port of Aabenraa. The company has signed an agreement for a larger area at the site of the port. For the Port of Aabenraa, the contract with Mibau Stema represents the most economically significant agreement in the port’s history.
Mibau Stema, which employs around 500 people across seven countries, identifies strong future growth potential in expanding its operations at the Port of Aabenraa.
“We are already very satisfied with our collaboration with the Port of Aabenraa, which is Denmark’s most efficient bulk port,” says Mibau Stema’s Managing Director Denmark, Rolf Bonnichsen. “When we assess the future market for raw materials against the availability of port areas, we achieve an even stronger position with additional areas at The Port of Aabenraa. This is due to the combination of the port’s geographical location and the ability to accommodate vessels with a draft of up to 18 metres. This ensures that the port is future-proofed for our upcoming ships.”
However, the agreement with The Port of Aabenraa is not only crucial for Mibau Stema in Denmark. As one of Europe’s leading raw material operators, the collaboration with The Port of Aabenraa is also important for Mibau Stema’s other European activities.
It is essential for us to stay ahead of developments,” explains Mibau Stema’s CEO, Claus Boisen. He adds, “It is not just the Danish raw material market that will face challenges due to resource shortages in the future. This applies to all of Europe, where we anticipate increasing demand for raw materials.
“Our supply chain requires us to have control over the entire process from our quarry to the ports that handle our products. Expanding Mibau Stema’s activities at the Port of Aabenraa is therefore no coincidence, as the port’s geographical location, close to both Northern Germany and the Baltic Sea, enables us to service a large market area.”
For Aabenraa Port, the historic agreement with Mibau Stema also carries significant strategic importance, strengthening the port’s position as one of Denmark’s key raw material ports.
“In the spring of 2024, the board of the
Port of Aabenraa approved the 2055 Development Plan. The agreement with Mibau Stema directly supports the port’s long-term ambitions outlined in the plan. We have unique facilities for handling bulk products. We must leverage these to strengthen our position as one of Denmark’s leading bulk ports,” says chairman of the board of the Port of Aabenraa, Erwin Andresen.
In general, The Port of Aabenraa is experiencing increasing demand for its attractive port areas.
“Our agreement with Mibau Stema is the most economically significant agreement the port has ever entered. However, we are currently experiencing great interest in establishing operations at the Port of Aabenraa. Several stakeholders have recognized the unique advantages of the port, making the future very exciting — not only for the port but also for Aabenraa and Southern Jutland,” concludes the director of the Port of Aabenraa, Henrik Thykjær.
A prevention cover being installed. These covers prevent tonnes of dry bulk from entering the water.
Race For The Baltic is a Swedish nongovernmental organization committed to combating the eutrophication of Baltic Sea waters. To maximize its impact, it collaborates with business owners to develop solutions that reduce phosphorus inflow into the Baltic Sea. The organization’s efforts encompass partnerships with port authorities, terminals, and stevedoring companies managing fertilizers, phosphate rock, grains, fodder, and other eutrophying materials in the Baltic Sea region.
It has introduced several innovative solutions to help terminal owners minimize pollution in port waters and along quaysides. One of the organization’s key innovations is the installation of prevention covers that bridge the gap between the quay and the ship’s side to prevent tonnes of dry bulk from entering the water. These covers have been successfully installed in Polish, Swedish, Lithuanian, and Danish ports. Some of them are complemented by recently financed self-unloading cradles. These cradles catch any dry bulk material that may fall, significantly reducing waste and saving valuable resources. Additionally, Race For The Baltic has invested in various cleaning machines and brushes to enable
terminal owners to clean quaysides more effectively.
In May 2024, Race For The Baltic hosted a roundtable in Gdańsk, Poland, uniting major stakeholders from Polish ports, including port authorities, terminals, maritime offices, the Polish Ministry of Infrastructure, and maritime media. This event focused on addressing the challenges associated with implementing proenvironmental changes in dry bulk fertilizer port handling. The outcome was the creation of the Catalogue of Best Practices and Technologies for Handling Dry Bulk Goods, a practitioner-developed document that outlines essential actions for ports to reduce material losses, promotes proper quays cleaning, and suggests the use of more developed technological solutions. Many leading Polish ports now use this Catalogue as a benchmark for environmental enhancements.
Race For The Baltic is actively engaged in educating port stakeholders about the environmental impact of dry bulk handling. In this context, they have presented their innovative solutions to port authorities, terminal operators, stevedoring companies, and crane operators across the Baltic Sea region. Its outreach extends to
the most prominent ports, such as Klaipeda, Riga, Liepaja, Tallinn, Gda ń sk, Gdynia, Szczecin–Świnoujście, Landskrona, and Vordingborg, as well as smaller ports involved in handling dry bulk goods. This educational initiative is crucial in fostering the widespread adoption of best practices and technologies that mitigate the environmental effects of port operations.
More recently, Race For The Baltic has launched a new project, continuing efforts to improve dry bulk handling practices in ports, focusing on grain and fodder. The project involves building relationships, providing education, and co-financing proenvironmental solutions at major grain terminals throughout the Baltic Sea region. Additionally, the organization is active participants in international efforts funded by the European Union. The PortSHAZ project, part of the Interreg South Baltic Programme, addresses environmental hazards associated with dry bulk cargo operations in ports of the region. Its primary objective is to develop and implement best practices and innovative technical solutions to reduce dry bulk cargo leakage, including designing a protection cover suitable for smaller ports, and promoting dust-free operations.
The Port of Tallinn, the largest port authority in Estonia, plays a crucial role in maritime logistics and handling of various bulk commodities. In 2024, the total volume of bulk cargo processed at its harbours — Muuga and Paldiski South — exceeded 2.1mt (million tonnes), marking a 20% increase from 2023. Among all cargo types, bulk cargo, particularly grain and gravel, experienced the highest growth.
The main bulk commodities handled through the Port of Tallinn harbours for both export and import include: Grain: Primarily consisting of locally v grown wheat, barley, and oats. Estonian grain production grew by 9% last year, reaching 1.3mt. The largest share of the harvest was wheat (57%), followed by barley (24%), oats (10%), and rye (6%). Muuga Harbour played a critical role in exporting Estonian grain, with 55% of the total harvest (710,000 tonnes) reaching global markets, including Europe, Nigeria, Saudi Arabia, and Senegal. Muuga Harbour is home to one of the largest grain terminals in the Baltic region, with an annual capacity of up to 5mt. Gravel, mainly processed at Muuga v Harbour, imported from Nordic countries, and used locally for road construction, repairs, as a de-icer, and in concrete production. Scrap Metal is primarily handled at v
Paldiski South Harbour by the Kuusakoski terminal.
Other dry bulk cargoes handled at the Port of Tallinn Include wood pellets, fertilizers, peat, salt, and crushed glass.
The Port of Tallinn operates as a landlord port, providing land, infrastructure, and safe navigation in its harbours. The cargo terminals operating within the harbours handle the superstructure, including cranes and equipment for processing and storing various cargo types. The primary users of the Port of Tallinn for bulk cargo handling are terminal operators processing an extensive range of materials:
In Muuga Harbour: HHLA TK v Estonia, PK Terminal, MGT Muuga Grain Terminaal, Bulk&Tank, Stivis.
In Paldiski South Harbour: ESTEVE, v Kuusakoski.
The port infrastructure supports efficient handling and storage of large bulk consignments making it a competitive choice for bulk cargoes’ export, import and transit.
To stay competitive, the Port of Tallinn focuses on several key strategic initiatives. These include: aiming to become the most innovative port in the Baltic Sea region by offering digital solutions, advanced logistics
and value-added services; implementing green initiatives to reduce emmisions and transition to alternative fuels; and expanding and modernizing port facilities to handle larger volumes and more diverse types of cargo.
HHLA TK Estonia expanded its warehouse capacity in 2024 by 4,000m2, by which warehousing facilities totalled to 86,500m² of specialized covered storage halls, complemented by extensive open areas. This addition allows the terminal to handle up to 500,000 tonnes of bulk cargo annually.
PK Terminal plans to expand its’ fleet of cargo handling machines with a SENNEBOGEN 885 G crane (operating weight 320 tonnes), to enhance the terminal’s ability to handle larger vessels. By using it’s specially developed program, the terminal offers fast turnaround of trucks, easy reporting and document processing, and allows the customers to check the stock of the item in the warehouse, ascertain the quantities of the items that have moved in and out, and plan their logistics.
Smart Port application implemented by the Port of Tallinn — an intelligent system which automates the vehicle traffic, shortens the time spent by trucks in port
areas and contributes to efficient logistics of bulk cargoes.
Muuga Harbour will be the only port in the Baltic States to host Rail Baltica cargo terminal.
Rail Baltica is a rail transport infrastructure project with a goal to integrate the Baltic States in the European rail network. The project includes five European Union countries — Poland, Lithuania, Latvia, Estonia and indirectly also Finland. It will connect Helsinki, Tallinn, Pärnu, Riga, Panevežys, Kaunas, Vilnius and Warsaw.
Integration with the Rail Baltica project will undoubtedly enhance connectivity and logistics efficiency of Muuga Harbour. A railway with the European gauge (1,435mm) will allow easier trade with Western Europe.
Muuga Harbour has a free zone that offers flexible customs procedures, making it an attractive hub for transit and distribution. The main advantage of the free zone is a more facilitated procedure of performance of customs formalities.
The Port of Tallinn also has industrial parks with free plots in Muuga and Paldiski South Harbours — totally 115 hectares of development space for dry bulk operators, producers, and industrial businesses seeking a location at the heart of a multimodal transport hub.
With direct connections to sea, rail, and road, these parks provide the ideal setting to optimize logistics, reduce transportation costs, and streamline supply chains.
The Port of Tallinn is managing four ports, of which Muuga and Paldiski South harbours are among the main cargo harbours in Estonia. The company is also active in shipping and real estate.
TS Laevad OÜ, a subsidiary company of the Port of Tallinn, operates a ferry service connecting Estonian mainland with the islands of Saaremaa and Hiiumaa.
Two other subsidiaries of AS Tallinna Sadam are TS Shipping OÜ, providing icebreaking services with the multifunctional vessel BOTNICA, and Green Marine AS, offering waste management services in ports.
The company was founded in 1992 and is publicly listed on the Nasdaq Tallinn Stock Exchange since 2018. The number of the shareholders exceeds 24,000. It plays a crucial role in Estonia’s economy, handling both cargo and passenger traffic.
Last year HHLA TK Estonia multimodal (container, general cargo/bulk, RO-RO) terminal in Tallinn/Muuga: expanded its facilities by adding three newly built warehouse sections.
This makes it the largest warehouse operator in the region, providing diverse storage options for pellets and grain. The terminal now features 86,500m² of specialized covered storage halls and extensive open areas.
With this expansion, the terminal can handle up to 1,000,000 tonnes of bulk cargo annually, solidifying TK Estonia’s role within its extensive logistics network as well as its position as a key player in the Baltic logistics sector.
The facilities include three solar parks installed on the warehouse roofs, with a combined capacity of 310kW peak. This renewable energy integration ensures that a significant portion of the loading operations is conducted with minimal greenhouse gas emissions
The main user of solar energy is the terminal’s new Mantsinen 120 DER mobile hydrocrane handles up to 620 tonnes of
bulk cargo per hour and combines electric and diesel power for top-notch efficiency and flexibility — a first of its kind in the Baltic!
The terminal’s self-service terminals at the gate barriers enable a fully automated process, eliminating the need for paper or checks for drivers transporting general and bulk goods.
The lorry load is automatically weighed and recorded by the system, both when entering and leaving the truck.
The main good handled at the terninal is grain, pellets, gravel, module houses, break bulk, paper, lumber, sawn timber, metal, food products.
Copenhagen Merchants Group has operated since 1977 as a neutral and global agriculture commodity broker. It has since developed a significant expertise within shipping, logistics, and bulk terminal operations across various regions. One of the key areas where the group has established a robust presence is in the Baltic region, where its terminals and capabilities are a testament to its operational excellence.
The Baltic region serves as a strategic hub for Copenhagen Merchants Group, providing crucial access to key markets and facilitating the efficient movement of agricultural commodities. The group has continuously developed its portfolio of terminals designed to handle large volumes of grains and other dry bulk products, ensuring seamless logistics and delivery for partners and clients.
Copenhagen Merchants Group’s terminals in the Baltic region are equipped with modern facilities that include: high-capacity storage silos and v warehouses; advanced loading and unloading v systems; drying equipment and installations to v ensure product quality; bagging and storage facilities to v accommodate smaller as well as big bag activities; comprehensive quality control v laboratories; and efficient transportation links to rail v and road networks. These facilities enable the group to
handle and process large quantities of grain and other dry bulk products with precision and efficiency, ensuring clients’ products are handled with care and as per best practice standards to secure quality in all aspects of the operations.
The group’s operational capabilities in the Baltic region are bolstered by its commitment to innovation and long-term development with partners. Copenhagen Merchants Group employs advanced technologies to optimize logistics, reduce turnaround times, and enhance overall efficiency. Some of the key capabilities include: real-time inventory management v systems; automated handling and processing v equipment; dedicated quality assurance teams v customized logistics solutions tailored v to client needs; breakbulk storage and handling v equipment; and
liquid storage in selected locations.
These capabilities ensure that Copenhagen Merchants Group remains a reliable partner for a mix of clients and customers as well as agricultural producers, sellers and buyers in the Baltic region. With an extensive network of 11 terminals across the Baltic region spanning from Denmark, Sweden, Latvia, and Poland it offers clients variability and solutions suitable across differing trade lanes.
Copenhagen Merchants Group is continuously looking to develop its terminal business by expanding both services and locations, delivering efficient handling and storage services. The existing portfolio of terminals is both able to handle smaller coaster sized vessels as well as Handy- and Supramax vessels in selected locations.
Copenhagen Merchants Group hold a range of business activities, and while global agri commodity brokerage remain at the core of the business several new activities have been added as stand alone businesses. This include bulk freight operations with own vessels, dry bulk terminal operations together with partners and own locations, production of plant based ingredients for feed, food and other specialty segments, and digital agri commodity market intelligence via CM Navigator.
In conclusion, Copenhagen Merchants Group’s terminals and capabilities in the Baltic region exemplify the group’s dedication to excellence, innovation, and long-term development. With cutting-edge infrastructure and a focus on client-centric solutions, the group continues to strengthen its position as a neutral leader in the agricultural commodities sector.
Lübecker Hafen-Gesellschaft (LHG) is steadily expanding its breakbulk and bulk cargo operations, reinforcing its position as a key player in the logistics and port services sector.
While ro-ro cargo remains a core business, LHG is strategically investing in its universal port services and has already succeeded in attracting cargo.
ENHANCED CAPABILITIES WITH THE NEW SENNEBOGEN EXCAVATOR
LHG recently commissioned a state-ofthe-art hybrid excavator from Sennebogen that has quickly proven its versatility and efficiency. This 20-tonne machine, featuring a 12-metre ‘banana boom’ with a reach of up to 20 metres, is capable of accessing ship holds as deep as eight metres. Equipped with a variety of gripping modules, the excavator demonstrated its performance during its inaugural operation at the Nordlandkai terminal, where it rapidly cleared bigbags from a bulk cargo vessel.
“This new excavator gives us an additional handling potential of 200,000 big bags for the current year,” says LHG’s managing director, Sebastian Jürgens.
STRENGTHENING BULK AND BREAKBULK OPERATIONS ALONGSIDE RO -RO
While ro-ro traffic remains a priority, LHG is broadening its cargo portfolio by intensifying its efforts in handling loose bulk goods such as fertilizers and animal
feed. Historically, the Nordlandkai terminal has managed around 400,000 tonnes of bulk cargo annually, and the new equipment is expected to enhance this performance.
LHG is also seeing increased demand for handling construction materials for major infrastructure projects in SchleswigHolstein, Germany’s northernmost state.
“This includes mineral aggregates for road construction to support power line infrastructure, as well as track materials for railway projects,” Jürgens explains. “Lübeck’s location is ideal for these
logistics operations.”
The company is also tapping into new markets with the import of Canadian larch — a substitute for the sanctioned Siberian larch. Delivered in containers via the port of Hamburg and subsequently transferred to Nordlandkai, this wood product is stored and reloaded on demand, underlining LHG’s capability to offer comprehensive and flexible logistics solutions.
RECORD SHIPMENTS AND FUTURE PROSPECTS AT NORDLANDKAI
The Nordlandkai terminal itself is a multifunctional hub, boasting 170,000m2 of shed space alongside covered rail tracks and handling areas that enable weatherindependent operations. Recently, the terminal garnered headlines by handling Lübeck’s heaviest project cargo to date — two transformers weighing a total of 572 tonnes were efficiently transferred from a coastal motor vessel onto a low-loader. This record-setting operation is just one example of LHG’s growing capacity, with additional heavy cargo shipments already in the pipeline.
“The demand for breakbulk and bulk cargo handling remains consistently high,” emphasizes Jürgens. “By developing the universal port concept at Nordlandkai, we can operate with even greater flexibility and offer our customers performancedriven solutions with additional logistics services.”
The Port of Gdynia is a modern universal port specializing in the handling of general cargo, mainly unitized, transported in containers and in the ro-ro system, based on a developed network of multimodal connections with hinterland, regular shortsea shipping lines and ferry connections.
The Port of Gdynia is a rapidly growing Polish seaport with a convenient location. Known for its strong brand and highquality services, it is a universal port with significant social and economic potential.
The Port of Gdynia is also an important link of the Baltic-Adriatic Corridor.
After more than 100 years since its establishment as the key hub for Polish foreign trade, the Port of Gdynia is now embarking on an ambitious investment program to expand its handling capacity. The main objective of this project is to accommodate larger container and bulk vessels, with a maximum length of 400 metres, a width of 58 metres, and a draft of up to 15 metres. Additionally, the investment aims to improve navigation conditions and enhance the safety of hydrotechnical structures. The project includes the reconstruction of four kilometres of the Port Canal and approximately 1.5 kilometres of quays.
With approximately 27mt (million tonnes) handled in the port last year, the Port of Gdynia presents a dominant position in the Baltic Sea Region in terms of throughput. More than 40% of the port’s handling structure is responsible for handling of bulk cargo. In 2024, the largest share of bulk cargo was agricultural products.
The Port of Gdynia plays a pivotal role in ensuring food security, having handled around 20% of all agro-cargo that passed through the Baltic ports in 2023. This underscores the port’s prominent position as a key grain hub. Beyond grains, the port also manages vital feed products, including soybean and rapeseed meal. In light of the current geopolitical landscape, the Port of Gdynia recognizes that the concept of security is evolving, extending beyond military concerns to include both food and energy security.
The Port of Gdynia is the largest agricultural port in the Baltic Sea Region, which handled nearly 6.8mt in 2023. Despite a decline in 2024 to 5.6mt (with a dynamic of nearly 83%), its market position remains strong. Several terminals handle cargo in this segment, including HES Gdynia Bulk Terminal, OT Port Gdynia, Mondry Terminal Gdynia, and SPEED. The
agriculture cargo sector plays a crucial role in Port Gdynia, which is reflected in ongoing investments by both the Port of Gdynia Authority and private operators. In the upcoming months, the modernization of the Indyjskie Quay, home to a dedicated grain terminal, will be completed. Additionally, specialized storage facilities for agricultural products are being built at HES Gdynia Bulk Terminal, significantly increasing its handling capacity in this segment.
Apart from agricultural products, fossil fuels play a crucial role in the Port of Gdynia’s cargo structure, which is driven by geopolitical factors and the diversification of incoming shipments. The Fuel Handling Station, located on the inner side of the breakwater, is primarily responsible for receiving diesel.
Given the ongoing war in Ukraine, the importance of a strong fuel station is even more significant. In 2024, fuels accounted for more than 11% of the port’s total throughput. Currently, the facility can handle vessels of up to 80,000dwt with a draught of 11.5 metres. After expansion, these features will increase to 170,000dwt with a draught of 14.2 metres. Additionally, the annual handling capacity will double from 3mt to 6mt.
Doubling the handling capacity of the fuel base is a significant step toward strengthening Poland’s energy security. This expansion will not only enhance the port’s ability to manage fuel efficiently but also ensure a more stable and reliable supply of energy in the face of ongoing geopolitical challenges. It underscores the importance of maintaining robust
infrastructure to support the country’s energy needs and future growth.
The amount of bulk cargo handled at the Port of Gdynia depends on the macroeconomic situation, which has been affected by ongoing war in Ukraine since 2022. In recent years, the Port of Gdynia has seen a significant increase in the import of coal and coke. Thanks to the port’s available handling capacity, it was able to manage the higher volumes of coal arriving by sea. Before Russia’s invasion of Ukraine, Russian coal was delivered to Poland by rail. With sanctions on Russia and the need to diversify its sources, coal is now arriving from more distant overseas locations. The port’s versatility and the flexibility of its terminals have allowed us to effectively use the port’s potential and ensure energy security of Polish economy. In 2024, coal and coke transshipments made up just over 4% of the port’s total throughput. The volume handled in 2024 has returned to the levels and trends seen before the economic disruptions.
In conclusion, terminals operating in the Port of Gdynia are investing independently in increasing their handling capacity. New warehouses are being constructed, including those for handling agricultural products. The tender for the grain terminal at the Port of Gdynia is currently underway. The new tenant will enhance the annual cargo handling potential. Among companies involved in bulk handling are: HES Gdynia Bulk Terminal Ltd., Baltic Bulk Terminal Ltd., PERN, OT Port Gdynia Ltd., SPEED Ltd., AALBORG Portland Ltd., ALPETROL Ltd., Chane Terminal Gdynia and Grain Terminal.
In the ever-evolving landscape of Baltic ports, efficient dry bulk handling is key to ensuring smooth operations. At CONVIR JSC, based in Kaunas, Lithuania, nearly 20 years of experience in material handling drives the company to deliver innovative and reliable conveyor solutions tailored for high-demand port environments.
CONVIR JSC’s equipment is designed to handle a wide range of bulk commodities — including coal, aggregates, mulch, grain, scrap metal, and more — ensuring seamless loading and unloading processes. With a focus on versatility and efficiency, its solutions are trusted by major port and terminal operators who require robust systems that minimize downtime and maximize throughput.
A standout in CONVIR JSC’s product lineup is the Convir MTTU2200/20 Truck Unloader. This radial truck unloader is engineered to continuously unload trucks directly into train wagons or barges, making it an ideal solution for highthroughput operations. Its design supports efficient material flow, reducing cycle times and improving productivity. Whether dealing with heavy materials like coal and aggregates or more delicate products like grain, the MTTU2200/20 adapts to diverse applications, ensuring that dry bulk materials are handled with precision and care.
MTTU2200/20 Truck Unloader.
Adding to the company’s suite of dynamic solutions is the CONVIR TSP-360, a tracked stacker conveyor with a 360° radial function. This track-mounted mobile conveyor is specifically designed for stockpiling materials from secondary equipment, maximizing storage volumes while ensuring flexibility and efficiency. Its compact design allows a single unit to be packed into a 40ft HC container, making global transport cost-effective and
straightforward. On-site assembly takes only one day, with typical setup times under ten minutes — greatly reducing the need for extensive civil works and planning permissions. This versatility not only supports short-term projects but also enhances resale value for long-term applications.
At CONVIR JSC, continuous innovation is at the heart of its competitive strategy. By integrating advanced control systems and modular design concepts, the company’s conveyors are built to deliver reliable, highperformance operation even under the most challenging conditions. These technological advancements help its major clients in the Baltic region and beyond optimize their operations, reduce maintenance costs, and achieve higher productivity levels.
As Baltic ports continue to modernize and expand their dry bulk handling capabilities, CONVIR JSC remains committed to pushing the boundaries of engineering excellence. Its ongoing investments in research and development ensure that it remains at the forefront of the industry, providing solutions that meet the evolving needs of port operators and bulk material handlers.
OT Logistics, a company listed on the Warsaw Stock Exchange, is the largest and most versatile port operator in Poland and one of the largest operators in the Baltic Sea Region. The OTL Group offers comprehensive logistics solutions under a one-stop-shop model, including sea freigh services, port services, and end-to-end delivery, regardless of cargo type or mode of transport. The company’s key cargo segments include agricultural products, containers, construction materials, fertilizers, general cargo, metallurgy, energy, and roll-on/roll-of (ro-ro) services.
The Group owns two major deep-sea port terminals: OT Port Ś winouj ś cie (OTPŚ), located in northwestern Poland, a rapidly growing bulk cargo terminal, and OT Port Gdynia (OTPG), situated in northern Poland, the country’s most versatile seaport with a ro-ro terminal. The annual transshipment potential reaches 8mt (million tonnes) at OTPŚ and 5mt at OTPG. The terminals can accommodate vessels with a draught of 13.2–13.5 metres in the case of OTPŚ and 14.5 metres in the case of OTPG.
Both terminals are being continuously developed, among others, through investments in state-of-the-art, efficient, and versatile port infrastructure, as well as by expanding handling capacities. These efforts aim to enhance the competitiveness and efficiency of services while increasing the ports’ flexibility and versatility.
In 2025, the expansion of the agro
terminal in Świnoujście will be completed, making it one of the most advanced facilities for automated grain transshipment, with a throughput capacity of 2mt per year. Ultimately, the terminal is designed to handle transit cargo from markets such as Ukraine, western Poland, and potentially eastern Germany. As of February 2025, OTPŚ has also initiated container handling in co-operation with Eimskip, an Icelandic shipping company.
At OT Port Gdynia expansion of the grain terminal and the development of the ro-ro terminal are underway. These projects will double both transshipment capacity and agro cargo throughput volume increasing the storage base to 160,000 tonnes of single-load cargo and launching rail deliveries for products of this type. In 2024, a new ro-ro shipping line was inaugurated in partnership with Lakeway Link, connecting Gdynia with the Port of Södertälje in Sweden.
The OTL Group continues
implementing automation and cutting-edge digital solutions across its port terminals. These initiatives streamline key processes and help reduce operational costs. For instance, at OTPŚ, advanced IT systems are being developed to provide customers with dedicated interfaces, enabling realtime monitoring of storage and reloading processes in real time.
In 2025, the Group will focus on enhancing and automating business processes, while further advancing the digitalization of its logistics services to boost operational efficiency and reduce costs. Infrastructure and superstructure modernization will also remain a priority to ensure high performance and further improve service quality. The modernization of infrastructure and superstructure will also continue to ensure high efficiency and quality of our services. Port assets are key to the OTL Group’s operations with seaports playing a strategic role in the global economy.
YILPORT Gävle is part of the Nordic terminal portfolio of YILPORT Holding, a global port operator that ranks among the world’s top ten port operators (Drewry 2024). YILPORT Nordic was established in 2015 with operations in Port of Oslo, where Norway’s largest container terminal is located. The company then expanded to Sweden just a year later, taking over the port operations in Gävle, the largest port on the Swedish east coast.
Additionally, YILPORT Nordic operates Stockholm Nord, an inland terminal near Sweden’s capital that enhances their capacity to serve Sweden’s largest consumption area with imports through their dedicated rail shuttle between Gävle and the capital.
YILPORT Gävle is located in Port of Gävle, just two hours north of Stockholm within the robust industrial Mid-Sweden region. As such, YILPORT Gävle is an important link to the global markets for their main customers — Sweden’s core industries — which includes paper mills, steel producers, and sawmills.
A wide range of bulk commodities pass through YILPORT Gävle’s bulk terminal with the primary cargo handled being sawn timber, steel, paper, and pulp, which are all important to Sweden’s export-driven economy. Additionally, the terminal handles a significant amount of project cargo such as windmills and housing modules.
The terminal’s role extends beyond handling cargo at the quay. A number of large warehouses and quayside areas are available for intermediate storage of goods, accessible through rail and with great connections to main highways leading
north, south, and west.
Some areas and warehouses are dedicated to timber, steel and paper products in YILPORT Gävle’s Container Freight Station (CFS) segment. At the stations, they receive, store, containerize and transport the customer’s cargo to the container terminal. One example of many improvements made in these segments is the world’s first automated high bay warehouse for paper rolls located in a port which YILPORT Gävle built a few years ago. This warehouse stands as a symbol of innovative port-centric solutions with its automated overhead cranes and conveyor belts, allowing for efficient handling of goods destined for global markets, meeting customer requirements for both short-
term storage and quick turnaround times.
As port operators in a constantly evolving market, YILPORT Gävle remains committed to continuous improvement and looking at innovative ways to expand its infrastructure to meet the increasing demands of the region. The company is actively investing in sustainability initiatives in all terminals aimed at reducing carbon emissions and enhancing operational efficiency. Notably, two of its mobile harbor cranes were recently converted from diesel to electric, and the company has replaced all diesel fuel with Hydrotreated Vegetable Oil (HVO), a cleaner, more eco-friendly alternative.
Globally, YILPORT calls itself a game changer in port operations.
The Weglowe Quay in the Inner Port is to be rebuilt. Port of Gdansk Authority SA signed an agreement with the general contractor, Budimex, on 10 March. Thanks to this investment, the Inner Port is going to become even more attractive to logistics operators and carriers.
The agreement was signed by the Management Board of the Port of Gdansk: President Dorota Pyc, Vice-President for Finance and Security Alan Aleksandrowicz, and Vice-President for Infrastructure Krzysztof Kaczmarek. The General Contractor, Budimex, was represented by Antoni Ciepielewski.
This undertaking is another task carried out as part of the project ‘Improvement of the infrastructure of the Port of Gdansk together with an analysis of the implementation of the OPS low-emission system for the sustainable development of the TEN-T network’, co-financed in 85% from the Connecting Europe Facility (CEF 2). This project includes the comprehensive reconstruction of almost 2km of quays in the Inner Port. As part of this package, the Rudowe III and Bytomskie Quays are already undergoing modernization. The Wislane Quay is next in line.
“This investment is sure to bring huge benefits to our region and the Port of Gdansk. It should significantly increase operational flexibility and cargo handling efficiency, resulting in an increase in port turnover. Moreover, preparing the
infrastructure for the implementation of green technologies is sure to raise our ecological standards”, says Dorota Pyc, president of the Port of Gdansk.
Weglowe Quay, located in the Górniczy Basin, has played a key role in bulk cargo handling for decades. The Górniczy Basin was established in the first half of the 20th century as a strategic element of the port’s cargo handling infrastructure for the export of coal and metal ores. It was an important part of Poland’s economic map, connecting Górny Slask and Dabrowa Basin with international markets.
Currently, due to its poor technical condition, part of the Weglowe Quay is not used for ship service and cargo handling. Under the recently signed agreement, a new 540-metre-long quay with a slab structure is to be built. The work is to be carried out in two stages. The first part
shall cover 252m of the quay, the next one 294m. A reinforced concrete pavement, a rail track and crane rails are to be constructed on the quay. The quay is also to be fitted with 1,000kN bollards and spot fender equipment. The project also includes the construction of new water supply networks, a rainwater drainage system with a purification system and an electricity grid. Dredging work at the quay is to be carried out to a depth of 11.20 m (current depth is approximately 8m).
The aim of the investment is to adapt the quay to cargo handling with LHM 550 and Mantsinen 300 self-propelled equipment. Currently, this is impossible due to the lack of a surface, but it is required to adapt the quay for ships with a maximum draught of 10.60m and a load capacity of up to 100,000dwt.
The investment is worth 127 million PLN and is expected to be completed by the end of 2027.
Unloading
Associated British Ports (ABP) is the largest port operator in the UK, with 21 ports across England, Wales and Scotland
ABP’s ports on the Humber handle and facilitate a wide range of dry bulk cargoes across four ports — Hull, Goole, Grimsby and Immingham. This is both directly through ABP’s own operations teams as well as by working with and supporting terminal operators, including Northwest Trading, Global Shipping and RMS. ABP serves a wide range of dry bulks customers in the region, including Viterra, Cefetra, Frontier, Drax, Yara, Thomas Bell, Origin, and PB Kent. These customers bring a wide variety of cargoes through ABP’s ports — from biomass to various fertilizer products — that supply the wider region’s farming needs, as well as Drax power station.
Over the past couple of years, ABP has continued to invest to support the dry bulks sector in a range of different ways. From investments made into improved port equipment, such as new cranes and loading shovels, to making improvements to existing sheds to help increase capacity or make them TASCC compliant, the company has continued to enhance its offering. ABP has also built new sheds and made operational improvements to increase performance and terminal capabilities such as introducing a new terminal operating system.
Further examples of recent improvements are its state-of-the-art shed spaces and the development of a completely new pusher blade that is now used at the Humber International Terminal (HIT). The attachment is a 9m spike for
use on the Volvo L150 loading shovel. It is used to bring down sheer faces to prevent cargo falls on persons or equipment. This improvement is in line with the company’s commitment to safety as a core value at ABP. In operations, the spike is pushed through the cargo, breaking it up and making the cargo face safe, also creating loose cargo which can be then loaded into a truck. This innovation was from Agriweld, a Volvo-approved supplier who have also produced pusher blades for the terminal.
Another significant investment has been in new sheds at the Port of Immingham for Viterra. These sheds have been constructed in two phases and will provide in 80,000te of undercover storage on the port. The second of the two sheds will be operational in May of this year.
Focusing on East Anglia, and ABP’s Ports
of Lowestoft and Ipswich, EDF has secured a land option agreement for three parcels of land. These include 15 acres on the West Bank of the Port of Ipswich and a 12.7 acre and 2.3 acre plots in Lowestoft for the support of the Sizewell C nuclear project. ABP already has extensive expertise in supporting major energy infrastructure projects, including Hinkley Point C. Both ports feature state-of-the art facilities including secure storage for bulk materials and robust quayside infrastructure for heavy and complex cargo. Lowestoft has recently completed a £35 million transformation with the completion of the Lowestoft Eastern Energy Facility (LEEF), which provides 345m of quayside and deep-water berths (7.5m draught). The facility has the potential to be used to transport aggregate for the
Sizewell nuclear project and for offshore energy projects in the Southern North Sea.
Ipswich has also seen a new shed tenant of fertilizer importers, Thomas Bell, move onto the port in January 2025. This marks the third port location across ABP to support Thomas Bell, in addition to Immingham and Newport, showing the strong relationship ABP has with its customers.
In recent years, ABP has made significant investments in port infrastructure in Ipswich, procuring its third fully electric crane, which represents a £1.5 million investment. This latest investment brings ABP’s total investment in port infrastructure to support the dry bulks sector to over £4.5 million since 2022. There have also been two new electric skids added to the port’s fleet of vehicles helping unload dry bulks from ships.
Significant investment in ABP’s ports is helping not only retain existing customers but also attract new ones. Furthermore, Ipswich also introduced a New Terminal
Operating System at the end of 2023CommTrac V4. This has been deployed to help streamline the management of fertilizer operations and is the first to include the new Bagging & Blending functionality. It is the sixth deployment of the system across ABP’s network. It is also in use in Teignmouth, Hull (two terminals) King’s Lynn and Newport highlighting how ABP is striving to deliver on improving port operations for dry bulks.
At the port of King’s Lynn, a state-ofthe-art bulk storage facility, designed specifically for Azelis is set to be completed by the end of March 2025 and should be operational by May. Azelis is an innovation service provider, supplying speciality chemicals and food ingredients to more than 2,000 customers in the UK.
Totalling around £7 million, this project marks a significant investment in King’s Lynn and represents the largest investment into the port to date by ABP. The project has been constructed by Britcon; a multi-award-winning, carbon-
neutral construction company.
The facility measures an impressive 106 metres in length, 44 metres in width, and 10 metres in height and is designed to accommodate both loose salt and bagged products. Externally, it benefits from 5,000m2 of heavy-duty concrete paving to support operations. The facility design and construction includes LED lighting, the reuse of 3,000 tonnes of recycled aggregates and a sustainable surface water drainage system to reduce carbon and improve environmental outcomes. Following completion, Azelis will install a cutting-edge bagging plant and relocate it to the site, which they will lease. This move will optimize Azelis’ operations and support their asset-light business model through extending the current relationship with ABP.
ABP is looking to continue investment into dry bulk opportunities with a further 40,000te new build store in Immingham, which will be made available to current port users and any new interested parties.
When I founded Spot Ship in 2019, our goal was to provide a vessel position parser that could read three points of information from a typical vessel position email – the identity of the vessel, when and where it will become available for cargoes, writes James Kellet, Founder, Spot Ship.
Our competitors in the market, some of which have been around for over twenty years, can only deliver an accuracy of between 60–80%. However, it was and remains my belief that only once accuracy levels reach above 95% can the technology be properly adopted by the market. Spot Ship is the only solution on the market that can deliver these levels of accuracy. Imagine if your mail app only displayed 75% of your inbox — it would be unusable.
Since the early days, Spot Ship has grown massively and with our growth we have sought to expand our offerings with new parsing solutions to different sectors within the shipping industry. In the summer of 2024, we launched our cargo parser to the market — requiring six to eight data points, including charterer, cargo type, quantity, range, laycan, and load/discharge ports; significantly more complicated to extract data, particularly when project cargoes are involved!
Our latest offering, the port line-up parser, is our most sophisticated data extraction software yet and its development was not without significant challenges, not least due to the extreme inconsistency in data fields offered by different providers.
Lineup data details the scheduled arrivals and departures of ships at a port or terminal. This data includes the vessel’s name, expected arrival, expected berth, and departure times, the cargo it is
carrying or expected to load/unload, terminal and berth allocation, and the current status of the vessel (e.g., whether it is at berth, anchored, or expected).
What are the advantages of automating lineup data? To answer this question, we must first take stock of the current methods and processes that port agents or officials use to compile their lineups. As has been the case for decades, operators or vessel officers communicate a vessel’s itinerary and ETA via phone and email. Despite us now being a quarter of the way through the 21st century, it is not uncommon for this information to be written out by hand into log books or onto whiteboards before being copied into digital worksheets or PDF. Over the past few years, this system has begun to digitize and improve, with some operators adopting software that allows the ship’s crew to provide instant updates to port agents via a shared ‘workflow’ style system. Such software certainly stands to reduce the amount of manual data entry and inevitably reduce potential human errors, but its adoption within the industry is in its infancy, leaving the familiar yet limited Excel sheet as the de facto industry standard.
Once the information has been compiled by port agents into a digital document, in whatever fashion, the port lineups are then disseminated across the industry. Anyone who has spent any amount of time reading these lineups will know that their formats vary tremendously from port to port and from agency to agency. I have also seen wildly different documents from the same port a couple of weeks apart, clearly created by different individuals with their own preferences for organization. Common issues include
terminals and berths not being ordered uniformly and values lacking units, allowing for metric tonnes to be mistaken for CMB. The most common cause of confusion is undoubtedly the varying ways to format a date. Unfortunately, it appears that the American tendency to invert the month and the day has been adopted by wellmeaning port agents around the world, making it hard to determine if a vessel’s estimated time of arrival is, for example, on the 5th of March or the 3rd of May. When one then considers the thousands of ports around the world, the scale of the problem becomes immediately evident.
To solve this problem, Spot Ship’s AIpowered line-up parsers extract the data from the documents and produce the information in clean and easy-to-read tables. Combined with AIS tracking of the global fleet, which is supported by a litany of voyage algorithms and logic systems, our users can instantly see any discrepancies with the data that they have been pushed in a lineup compared to the live location of a vessel and its status as reported by the master on board. Simply put, if a vessel is scheduled to be at a berth in a specific terminal but is, in fact, sailing to an anchorage outside the port, Spot Ship will notify the user, allowing them to make any decisions necessary with greater speed and efficiency.
As well as Spot Ship’s platform users, we are also providing this AI solution to other largest tech companies in the industry who rely on Spot Ship to serve their own customers. As the maritime industry continues to digitize, these collaborations will grow ever more important. The problem is simply too big for any single corporate entity to solve alone.
Flow control valves and more: how Vortex takes the lead in offering the best equipment for dry bulk material
THE DUAL ROLE OF FLOW CONTROL VALVES: DIVERTERS AND SLIDE GATES
Flow control valves in the context of dry bulk material handling encompass two principal configurations: diverters and slide gates, each serving a unique function within systems. Slide gates, also commonly referred to as ‘knife gates’, ‘gate valves’, ‘guillotine gates’, ‘isolation gates’, and ‘flat slide valves’, are designed to shut off or allow the flow of dry bulk materials through conduits. They operate on a straightforward mechanism involving a sliding plate that moves perpendicular to the material flow, thus enabling full control over the stoppage and resumption of material passage. This feature is especially crucial in processes requiring precise batch delivery or when maintenance work necessitates the temporary cessation of material flow.
On the other hand, diverters also commonly referred to as ‘K-valve’, ‘A-valve’, ‘Pant leg valve’, ‘Distribution gate’, ‘Y-diverter’, ‘T-diverter’, ‘flap diverter’, and ‘bucket diverter’, play a critical role in routing materials to different destinations from a single source. Equipped with a mechanism to alter the direction of flow, diverters can channel materials into multiple outlets, making them indispensable in facilities requiring efficient distribution of materials to various processing lines or storage units. This capability not only optimizes material handling efficiency but also enhances system flexibility by accommodating changes in production needs or layouts without necessitating major alterations to the pipeline infrastructure.
Both diverters and slide gates embody the essence of flow control valves by offering operators precise, reliable control over the movement and destination of dry bulk materials.
Their integration into material handling systems underscores the advancement in industrial processes, where efficiency, safety, and adaptability are paramount.
‘Dry bulk materials’ refer to granular, powdered, or particulate substances that are handled and transported in bulk form. These can range from grains, flour, and sugar to minerals, chemicals, and construction materials like cement and sand. Characterized by their ability to flow
freely when loaded or unloaded, dry bulk materials pose unique challenges in terms of containment, control, and transport. Effective management of these materials necessitates specialized equipment that can accommodate their varied properties, such as density, abrasiveness, and moisture content. Understanding the specific characteristics of the dry bulk materials being handled is crucial for selecting the appropriate flow control valves — diverters and slide gate — that will ensure smooth, efficient, and safe operations within industrial systems.
The evolution of flow control valves in dry bulk material handling is a remarkable tale of innovation, adaptation, and technological progress that reflects the wider growth of industrial methodologies. Tracing back to the Industrial Revolution, the birth of control valves emerged from the growing necessity for effective material handling solutions in burgeoning factories and mills. This era saw the development of the first rudimentary control valves, manual systems designed with simple mechanisms to manage the flow of granular substances like coal, grain, and sand from storage containers.
Initially, control valve designs faced numerous challenges due to the constraints of available construction materials and manufacturing techniques. Precision in fit and sealing technology was notably lacking, frequently leading to material leakage, and hampering accurate flow control. Additionally, these early valves were prone to wear and corrosion,
especially when used with abrasive or corrosive materials, necessitating regular maintenance and replacement. The manual operation of these systems further introduced safety hazards for workers, particularly in settings where hazardous substances were present.
Despite these obstacles, the vital necessity for control valves in handling dry bulk materials drove continuous enhancements. The advent of superior materials, such as stainless steel and advanced alloys, significantly improved the durability and operational lifespan of control valves. Moreover, breakthroughs in manufacturing technologies, including precision machining and welding, achieved tighter tolerances and a better seal, minimizing leakage, and enhancing control over material flow.
A pivotal advancement in control valve technology was the improvement in sealing technologies. Initial seal designs were basic, offering limited leakage resistance and failing to endure the abrasive qualities of some materials. Modern sealing technologies, however, have transformed, utilizing advanced materials and innovative designs to achieve exceptional sealing capabilities.
The integration of automation and control technologies marked a significant milestone in the development of control valves. The incorporation of electromechanical actuators, pneumatic systems, and subsequently, hydraulic mechanisms into valve designs facilitated remote operation, enhancing operator safety. Automation also allowed for more precise material flow control, increasing efficiency, and reducing waste.
In contemporary settings, the digitalization and incorporation of smart technologies have further advanced control valve technology. Modern valves are often integral components of sophisticated material handling systems, equipped with sensors and linked to central control units for real-time monitoring and adjustments. This integration has substantially elevated efficiency, safety, and reliability in dry bulk material handling processes, marking a new era of industrial capability.
THE IMPACT OF VORTEX ON THE EVOLUTION AND FUTURE OF FLOW CONTROL VALVES Vortex has distinguished itself as a trailblazer in the dry bulk material handling
industry, primarily through its innovative control valve designs and a forwardthinking approach that prioritizes customer needs, efficiency, and safety. What sets Vortex apart from its competitors is not just its products but its commitment to solving the complex challenges faced by industries dealing with bulk materials. Before Vortex, the industry regularly relied on valves designed for the Oil and Gas industry which proved too costly, inefficient, and unreliable.
Vortex challenged the status quo and revolutionized the control valve market with its patented designs, which continue to set the standard for efficiency, reliability, and safety.
At the heart of Vortex’s impressive success is its pioneering approach to the design and manufacture of control valves. Known for their durability, precision, and adaptability, Vortex’s flow control valves cater to a wide range of materials and industries. These valves feature innovative elements like live-loaded seals and wearcompensating hard polymer liners, which significantly reduce material leakage and extend the service life, even under the most demanding conditions. Vortex’s dedication to utilizing advanced materials and state-of-the-art manufacturing processes ensures their valves are adept at handling any application.
Vortex offers a comprehensive range of flow control valve solutions, each meticulously designed to address the distinct demands of different material handling scenarios. Whether it is for lightweight, free-flowing substances or heavy, abrasive materials, there is a Vortex control valve specifically optimized for the
task. For industries dealing with powders or granules that tend to stick or compact, Vortex provides valves with special coatings and liners to promote smoother flow, avoid blockages, and maintain consistent performance.
Conversely, for highly abrasive materials, Vortex has developed valves featuring reinforced structures and materials for superior wear resistance, ensuring durability and reliability.
Over its almost half century in the industry, Vortex has not only pioneered specific flow control valve designs and enhancements but has also secured 27 patents thus far, underlining its leadership and innovative spirit. Standout products include the Quantum Series Orifice Slide Gate and Wye Line Diverter, both exemplifying Vortex’s commitment to precision flow control and minimal maintenance. These valves boast Vortex’s patented design, featuring a unique liveloaded seal system for tight shut-off and leak-proof operation, along with a modular design for straightforward installation and easy maintenance.
Another significant advancement is found in the Titan Series Control Valves, engineered for handling heavy-duty and abrasive materials. The Titan Series incorporates hardened steel components making it robust enough to withstand the rigors of materials such as sand, gravel, and coal. The durability of these control valves is further enhanced by Vortex’s use of special sealing technologies and design that resist wear and tear, extending the operational life of the valves in even the most challenging environments.
This ability to provide tailored solutions stems from Vortex’s deep understanding of the complexities associated with dry bulk
material handling and its commitment to innovation. By considering factors like material characteristics (e.g., particle size, moisture content, abrasiveness), process requirements (e.g., sealing, flow control), and environmental conditions (e.g., temperature, humidity), Vortex ensures that each control valve not only meets but exceeds the operational demands of its application. Consequently, this level of specialization has not only cemented Vortex’s reputation as a leader in the industry but has also significantly contributed to maximizing operational efficiency and minimizing downtime for its clients across various sectors.
Vortex has also been pioneering in the integration of various control technology into its valve designs. Its control valves can be equipped with sensors and monitoring systems that provide data on position, material flow rates, and operational status. This information can be integrated into a centralized control system, enabling realtime adjustments and predictive maintenance, thereby reducing downtime, and increasing the efficiency of the material handling process.
These innovations underline Vortex’s commitment to providing solutions that not only meet the immediate needs of dry bulk material handling but also anticipate future challenges and opportunities for improvement.
Vortex’s influence on the evolution of control valves extends to its dedication to safety and efficiency. Through innovative designs and the use of advanced materials, Vortex has drastically minimized the dangers linked with valve operation and maintenance, including the risks posed by exposed pinch points. Valves with exposed pinch points can lead to serious injuries when operators or maintenance personnel accidentally come into contact with moving parts.
In contrast, valves lacking the sophisticated safety technologies characteristic of Vortex Control Valves put workers and operational settings at considerable risk. Traditional control valves, particularly those not designed for dry bulk materials, are prone to material spillage, which creates slip hazards and the risk of exposure to harmful substances. The absence of live-loaded seals and wearresistant materials often leads to frequent leaks, requiring constant maintenance and putting maintenance staff at risk of injuries during manual repairs.
Moreover, without the secure shut-off
and leak-proof performance offered by cutting-edge seal systems like those in Vortex valves, there is a heightened risk of cross-contamination.
This not only jeopardizes the quality of materials but also endangers worker health and product integrity. Older or less sophisticated valve designs, lacking precise flow control, can cause operational inefficiencies and safety hazards, including system blockages or overpressures that may result in blowouts or equipment failures. Facilities lacking these essential safety features are vulnerable to operational disruptions and the severe consequences of failing to meet industry safety standards and regulations.
Several businesses across various sectors have reaped the benefits of implementing Vortex’s control valve solutions.
In one case a prominent pastry mix
manufacturer, producing an astonishing 10,000 bags of donut mix daily, which in turn yields approximately 168 million donuts per day, relies on Vortex’s control valves for their production process.
Another case has a customer that utilizes a customized V-Notch Manual Titan Gate to meter and accurately control their flow of sand.
Despite its achievements, Vortex remains committed to working closely with customers to address the unique challenges and demanding conditions of various industries. The dry bulk industry’s wide range of materials means a universal solution is not feasible. Consequently, Vortex consistently dedicates resources to research and development, aiming to enhance and tailor standard equipment options for particular materials and settings. With a highly experienced
engineering and sales team, Vortex excels at tackling the toughest application challenges in the industry, offering an extensive catalogue of material handling solutions.
In conclusion, Vortex’s prowess in innovating control valve solutions has not only set industry benchmarks but has also paved the way for new standards in operational efficiency, safety, and reliability in dry bulk material handling. Through its continuous commitment to technological advancement in reliable standard equipment, tailored solutions, and dedication to customer satisfaction, Vortex exemplifies how forward-thinking and customer-centric engineering can result in substantial benefits for industries worldwide.
Vortex’s contributions to the field underscore the company’s pivotal role in transforming challenges into opportunities for efficiency and success.
The Port of Dover Cargo Business plays a pivotal role in the UK’s logistics and trade network, strategically positioned on the Short Strait, the busiest maritime passage in the world. As one of the country’s most strategically located deep-water ports, it empowers exchange by enabling seamless connections between markets, industries, and communities. Every cargo movement through Dover is an opportunity for trade, collaboration, and economic growth. Through continuous investment in infrastructure, technology, and sustainability, the port is committed to ensuring that trade flows efficiently, smartly, and sustainably.
The Port of Dover is continuously investing in cutting-edge equipment and operational efficiencies to enhance capacity and streamline cargo handling. Its recent acquisition of Liebherr cranes has significantly improved its bulk handling operations, offering greater lifting capacity, precision, and reliability. These investments
enable the port to handle a wider range of cargo types while maintaining the highest standards of safety and environmental responsibility. By leveraging technology and process optimization, the Port of Dover ensures that goods move faster, supply
The Port of Dover’s recent acquisition of Liebherr cranes has significantly improved its bulk handling operations.
chains remain resilient, and businesses stay competitive. The port’s flexible approach and strong client relationships allow it to tailor services to meet specific handling requirements, ensuring that it remains a trusted partner in trade.
Sustainability is at the heart of the Port of Dover’s operations, driving its vision for a world where trade is seamless, smart, and sustainable for all. Since 2007, it has reduced its carbon footprint by 95% and remains committed to achieving ambitious net-zero targets. By 2025, the port aims to achieve net zero carbon emissions for Scope 1 and 2 through alternative fuels, renewable energy integration, electrification of its landside fleet, encouraging cycling, and offsetting carbon emissions through natural and economic solutions.
Looking ahead to 2030, the port is taking this commitment further by eliminating net carbon emissions across Scope 1, 2, and defined Scope 3 categories, ensuring that any residual emissions are balanced through natural means. This will be achieved by minimizing carbon emissions in procurement and development while continuing investments in energy-efficient operations.
Beyond 2030, the port is collaborating with the wider port community, supply chain, and customers to establish a Green Corridor, an initiative that strengthens partnerships to drive sustainability across the entire logistics chain. The Port of Dover is also committed to continuous improvement in environmental performance, ensuring zero waste to landfill, eliminating pollution from its activities, reducing single-use plastics, minimizing emissions to air, and planning all construction projects to reduce their carbon impact. Through these efforts, it is closing the gap between trade and sustainability, ensuring that Dover remains a future-ready port that supports the global shift to greener logistics.
Recognizing the increasing demand for bulk material handling, the Port of Dover
has expanded its bulk grab operations to better serve key industries. Its enhanced capabilities enable the port to handle a wide range of dry bulk commodities, including aggregates, grain, gravel, steel, and timber.
With a focus on fast turnaround times, it ensures that cargo is handled quickly and efficiently, reducing delays and optimizing supply chains. Its ability to provide quick, responsive service while upholding the highest operational and environmental standards makes the port a vital partner in ensuring smooth, uninterrupted global trade flows.
Looking ahead, the Port of Dover is set to expand further, with new land becoming operational from mid-2026. This development will significantly increase its capacity for dry bulk cargo handling, closing the gap between market demand and infrastructure capacity. By expanding its operational footprint, the port will enhance connectivity, improve resilience, and provide businesses with the space and support needed to grow. This investment reflects its commitment to making trade more efficient and accessible, ensuring that exchange is not just possible, but optimized for the future.
Its location on the Short Strait provides unrivalled access to European and global markets, making the Port of Dover a preferred hub for businesses seeking to streamline their supply chains. Positioned at the closest crossing point between the UK and mainland Europe, it offers fast and reliable access that supports UK and European scheduled services, ensuring seamless connections for cargo movement.
Located in Kent, the port provides a port-centric solution that delivers
significant haulage savings by reducing inland transportation distances and optimizing supply chain efficiency. Additionally, the port’s quick inland traction to the Southeast and across the UK is supported by two strategic, highly managed road networks, the A2 and M20, providing direct connectivity to major logistics hubs, including London in under an hour. This accessibility ensures that cargo can be moved swiftly and efficiently, reducing transit times and enhancing supply chain resilience.
A key advantage of the port’s operations is its ability to offer flexible, client-centric services, ensuring that businesses can rely on it for tailored, responsive cargo handling solutions. By maintaining close relationships with its customers, it anticipates their needs and provide services that align with their evolving requirements.
Coupled with its fast turnaround times, the Port of Dover ensures that goods move quickly, reducing waiting times and maximizing efficiency at every stage of the logistics process.
As it continues to invest in infrastructure, technology, and sustainable practices, the Port of Dover is shaping the future of global exchange. Its vision is to create a world where trade and logistics are seamless, smart, and sustainable for all. Through strategic collaborations, continuous innovation, and a commitment to environmental responsibility, the port is building a port that not only meets today’s challenges but also anticipates the demands of tomorrow.
By working closely with its partners, clients, and the wider industry, the Port of dover is ensuring that it remains a leading gateway for efficient, sustainable, and world-class trade experiences. Thank you ...for proving us right. Advertising really does work.
To find out how you can benefit from advertising in the world’s only monthly dry bulk publication contact Andrew Hucker-Brown on Email: info@dc-int.com or Tel: +27 31 583 4360
Bagging/blending machines specialist, Bag and Bulk Handling (PTY) Ltd. (BBH), has recently announced its new NW6300 Bagging Controller.
“This unit combines the high-speed of our of advanced models with accuracy of our high-end unit,” says Neale Rampono, Director at BBH. “It comes with built-inselectable software for various applications, including net weighing and gross weighing. Additionally, it supports dual scale capability and offers multiple downstream interlock features making it adaptable for different operational needs,” adds Rampono.
“Our NW6300 Bagging Controller has been in the development and planning phase for 24 months,” explains Rampono, “during which we have conducted extensive research, testing and refinement to ensure optimal performance and reliability.”
T HE NEW NW6300 B AGGING CONTROLLER
ENHANCES EFFICIENCY AND PRECISION IN PACKAGING OPERATIONS IN SEVERAL KEY WAYS:
High-speed operations — it v maintains fast throughput, optimizing productivity while ensuring consistent output.
Precision weighing — with built in v net and gross weighing capabilities, it delivers highly accurate weights, reducing material wastage and ensuring compliance with standard weights.
Selectable software for flexibility – v this unit includes pre-set software options for different weighing
applications, allowing seamless adaptation to various packaging requirements, standard bagging, filling and in-line weighing.
Dual-scale capability — this feature v enables simultaneous weighing, further increasing efficiency and reducing downtime.
Advanced interlock features — this v system integrates smoothly with downstream equipment enhancing automation and minimizing manual intervention.
Simplified troubleshooting — while v it does not have remote access, any issues can be quickly diagnosed and resolved via phone call/email.
NW6300 approvals: v
- NTEP CC 15-00/Class III/IIIL 10 000d
- Measurement Canada AM-5980C
- ClassIII/III HD 10,000d
- EU Test Certificate
- UL/cUL Recognized
- Ce Marked
Operating from as early as 1999, BBH specializes in the design, fabrication and supply of high-quality bagging/blending machines throughout Africa.
According to Rampono the company “specializes in providing bespoke innovative solutions that are specific to our customers’ business requirements. This includes intake cargo handling systems and out-loading stations.” The company’s services also include consulting, installation, commissioning, maintenance and on-site training to ensure a seamless operation.
BBH’s bagging and weighing system equipment is designed to handle a wide range of commodities across various industries. These include: Agricultural products — grains, v seeds animal feed, fertilizers; Food products — flour, sugar, rice, v salt spices, coffee; Minerals and construction v materials — cement, sand, lime, gypsum; Chemical & industrial products — v powders, granules, resins, plastic pellets;
Other bulk materials — charcoal, v wood pellets, speciality powders.
“We combine speed with precision and high accuracy weighing,” says Rampono, “to minimize material wastage and maximize productivity.”
The company’s systems feature built in versatile selectable software for different applications, including net and gross weighing, dual capability, and downstream interlock features, making them highly adaptable to various industries.
“While some competitors rely on complex systems, our solutions are intuitive and easy to troubleshoot, with remote support available 24/7 for quick issue resolution.”
Designed for long-term performance, BBH’s machines are built with high-quality materials and components, ensuring lower maintenance costs and minimal downtime and enhanced durability and reliability.
... to open a can of trade disputes
President Donald Trump acting unilaterally on steel tariff is to set off reciprocal action by the targeted countries leading to trade disputes. The Trump move will neither revive the fortunes of the US steel industry nor will it bring world steel production in alignment with demand.
Long before Donald John Trump became President of the US for the first time in 2016, he invited the sobriquet maverick for the unconventional way he conducted his business and politics. The world is having a full taste of that in his second term as President Trump has proposed a tariff structure, which the US administration is in the process of implementing causing acute resentment among all US trade partners, including its
traditional close allies. Imports of steel along with the base metal aluminium are coming for highly punishing tariff barrier with the US to charge 25% import duty irrespective of the origin of the two metals. As a result of the change, steel tariff undergoes a substantial increase from the earlier 2.95%.
A paper by the Center for Strategic and International Studies, a Washington based think tank, tells US imports of steel and aluminium last year valued at an estimated $61bn had a share of 1.8% of total goods imports, raising doubts, if not concern about the move. But what did provoke Trump to do to steel and aluminium imports that would set off global outrage? The President does not hide his
disappointment that the country will be using imports to meet close to 30% of domestic steel requirements, similar to the situation obtaining in 2018. This is happening in spite of adequate capacity available within the US. What is not acceptable to Trump is as steel imports remain at an elevated level, “the domestic industry’s performance has been depressed, resulting in capacity utilization rates persistently lower than the 80% target level.”
Trump, on his own admission, is driven by the conviction that in the pursuit of ‘make America great again’ (MAGA), he will do whatever is needed, irrespective of reactions of trade partners. The US is traditionally a major producer of steel and
Peel Ports Group has set out its ambition to turn the Port of Liverpool into a global hub for steel after the port operator marked a record-breaking year for bulk imports at the site throughout 2024.
702,000 tonnes of bulk steel were processed at the port in 2024, coming from across the world including from South Korea, Vietnam, Taiwan, Turkey, and Europe.
The record-breaking figure, which surpasses the port’s previous record by more than 50,000 tonnes, follows significant investment by Peel Ports Group into infrastructure at the port as the company looks to bolster its support for the steel industry.
Peel Ports Group recently invested £2 million into the development of a new deep water bulk berth at the port’s Alexandra Complex, expanding its cargo handling operations.
Home to a deep water berth, the Port of Liverpool is able to accommodate a range of vessels, including Handymax bulk carriers.
Meanwhile, a further investment in 200,000ft2 of additional, inside storage space has been made in 2025 to expand Peel Ports Group’s coil and precious metals handling capabilities at the port.
Some 85% of the steel imported into the Port of Liverpool in 2024 was steel coil, set to be used across a range of industries including construction, automotive, agricultural, renewable energy projects, medical healthcare, and manufacturing.
Phil Hall, Mersey Port Director, Peel Ports Group, said: “The Port of Liverpool is a deep water gateway to global markets and we’re thrilled to achieve a record-breaking year for steel imports.
“The figures speak for themselves, showing the work we’re doing to meet our ambition of cementing Liverpool as the leading UK hub providing vital commodities to a range of industries. That’s further supported by our dedication to investing in the port’s infrastructure, market reach, our port-centric services, and our expert teams.
“We look forward to building on this success with our customers and developing this market leading proposition further.”
innovator of steel-related technologies. Germany-based data aggregator Statista figures show that the US steel industry has had a rollercoaster ride in production since 2006 when the output was a high 98.2mt (million tonnes). But because of the impact of coronavirus and the accompanying general economic downturn, production sank to 72.7mt in 2020. More recently in 2024, the US steel output slid 2.4% from the previous year’s 81.4mt to 79.5mt. Whatever the understanding of Trump, the process of globalization of the steel industry continues with groups in China, India and the European Union (EU) continuing to make cross-border investments in steel and supporting infrastructure. In line with that exercise, the Japanese Nippon Steel made a $14.9bn bid for US Steel in December 2023, promising at the same time billions of dollars of investment to replace the ageing infrastructure of the Pittsburgh-headquartered storied steelmaker. President Biden blocked the Nippon bid mainly to placate the trade unions fearing job losses. But that did not deter Nippon from pursuing a different kind of arrangement for US Steel.
During the Japanese prime minister Shigeru Ishiba’s recent visit to Washington, a new deal on US Steel was proposed that instead of Nippon Steel seeking majority ownership of US Steel, it would “invest heavily” in Pennsylvania-based steelmaker. While the agreement on Nippon investment and involvement in management of operations of US Steel remains to be finalized, the Japanese company has let it be known that whatever be finally the shape of the agreement it would be “in line” with Trump’s focus on manufacturing, job creation and promoting investment in the US. The new Japanese prime minister who, like his predecessor Fumio Kishida, wants to be on the friendliest possible terms with the US, will likely ensure that Nippon Steel works with US Steel the way Trump wants.
Experts are not able to fathom as to why Trump is acting unilaterally on steel tariffs instead of attempting to take allies such as the EU, the UK and Japan on board. His target may be the non-market China, which is found to be primarily responsible for the woes of the global steel industry. But as it turned out, Trump is putting the 25% duty on steel originating in any part of the world with no concession given to friendly countries. The impost is in addition to any existing tariffs.
What the US President is doing with steel and also aluminium, making their imports dearer, gives an idea of how radically the US trade policy is being
overhauled to create a fortress out of America. Even while a Trump objective is to force steel producing countries to desist from giving indefensible subsidies to steelmakers in various forms, resulting in building of surplus capacity and production, the fact remains China is not a steel exporter of significance to the US. The US steel imports were up 3.4% in 2024 to 26.5mt from 25.6mt in 2023. But because of the many trade barriers encountered since 2018, China could export only 508,000 tonnes of steel to the US last year or less than 2% of total American steel imports. The six major steel exporting countries to the US in 2024 were: Canada (6.39mt), Brazil (3.49mt), Mexico (2.85mt), South Korea (1.53mt), Germany (1.18mt) and Japan (944,000 tonnes).
But 2024 was the year when Chinese steel exports at 110.72mt, up 22.7% from 90.3mt in 2023 turned out to be the highest since 2015. What was the net impact of highly subsidized Chinese steel exports? As such exports undercut producers in the rest of the world, steel prices remained low eroding producer margin.
Expectedly, the torrent of Chinese supplies in an already surplus market inflamed global trade tensions with the EU, India and Japan, among others, becoming blunt critics of Beijing seeking a solution to domestic excess supply by flooding the world market with its steel. South Korea and Vietnam had to seek protection for its steelmakers by putting anti-dumping duties on some Chinese steel products. The point, however, remains that Trump’s action of slapping a steep duty will barely affect China since it has such little presence in US steel imports. But what is keeping steel prices low affecting industry profitability in free as well as non-market economies is
the presence of oversized surplus capacity. WSA says the estimated world crude steel capacity of 2.432bn tonnes in 2023 exceeded global steel output by 543mt. Furthermore, global steel excess capacity is projected to reach around 630mt by 2026, more than the total steel production in all OECD countries.
The pitfall of Presidential tariff orders in the form of retaliation by all affected countries could have been avoided had the Trump administration made a joint move with its allies, including the EU, to restrain non-market economies, particularly China from subsidizing the steel industry. In fact, a multilateral attempt was made back in 2018 by the EU and the US under the Global Arrangement on Sustainable Steel umbrella to build a tariff structure that would act as a disincentive for non-market economies to produce carbon-intensive and subsidized steel and aluminium. But negotiations did not make headway as the EU favoured a carbon border adjustment mechanism while the US stuck to its own tariff policy.
As the new US duty will have little, if any impact on voluminous Chinese export of steel, countries across the continents enraged by the American move have threatened reciprocal actions. No doubt, in the new acrimonious trade environment, several steel and aluminium exporting countries will have commercial disputes that will end up at the World Trade Organization (WTO) for resolution. But President Trump is convinced that his move will not only support about 80,000 jobs in the steel industry but it will also help in capacity revival and therefore, create new jobs. He, however, seems to be oblivious of the fact that such stiff tariffs will be hurtful for steel downstream industries where employment is in excess
of 12m will have to brace for price rises of products using steel.
Analysts are in consensus that steel exports by China will remain elevated in the current year too as the country’s property market faces weak recovery prospects and investment in infrastructure projects is experiencing moderate growth. The two sectors have more than half the share of China’s steel use. Fall in demand there was partly compensated by higher order for steel emerging from the manufacturing sector. But this could not be enough to arrest the fall in China steel use in 2024 by 4.4% to below 900mt. Analytics group S&P Global says: “China’s steel sector faces another year of sluggish domestic demand and narrowing options to ease the pain via exports.” At the same time, steel spreads are stabilizing in China in a sign that the industry is “gradually adjusting to downcycle conditions.”
Chinese steelmakers have the compulsion to use the export window to dispose of the considerable steel surplus caused by high production though in decline since 2020 when it peaked at 1.065bn tonnes and disappointing domestic demand. But exports are to become increasingly challenging in the face of rising protectionism.
Is there finally a hope that Beijing will be earnest in restructuring its steel industry in a way that will achieve the twin objectives of aligning capacity and production to principally domestic requirements and the national carbon emission targets. Significantly for the first time, China’s National Development and Reform Commission has recently recommended to the National People’s Congress in Beijing the restructuring of the steel industry through output reduction that should result in domestic steel prices improvement, end big
volume export compulsion and eliminate trade frictions. The Commission has said in a report: “We will introduce policies and measures for resolving structural problems in key industries… through industrial regulation and upgrading.” Even while experts say that China will be required to go for a “radical” shedding in capacity and production to improve the sector’s profitability, Beijing is yet to give any specifics on cuts. Whatever that may be, 2024 might have been the last year that China produced a billion tonne of steel.
The fact remains that whatever steel capacity China has shed since 2016 is just not enough either to strike a balance between global demand and supply and comply with its own steel related carbon emission reduction target. Besides phasing out the ageing, low productive and polluting mills, Beijing has mandated no fresh capacity building, except for capacity replacement by way of modernization. In this context, the Centre for Research on Energy and Clean Air (CREA) wants China to phase out at least 200mt coal-based blast furnace capacity over a five-year period. That is about 15% of the country’s steelmaking capacity or equal to total capacity of the European Union. Low domestic demand plus urgency to curb CO2 emission have left Beijing with no alternative to framing policies to bring capacity in alignment with market requirements. Restrictions at home and also pressure from a number of countries in Asia and Africa for investment in industry and infrastructure have led Chinese steelmakers to progressively step up cross-border investments. Such Chinese investment remains focused in ASEAN and some other Asian countries. According to one report, China alone accounts for over 60% of global “total
cross-border investment in new steelmaking capacity taking place around the world.”
In spite of surpluses leading China in particular to be an aggressive seller of steel in the world market, new steel capacity is coming up in ASEAN, the Middle East and India. India, which remains the world’s second largest producer with production up smartly by 6.3% to 149.6mt, is a unique case of fast rising domestic consumption driving new capacity creation by leading steel groups, including Tata Steel, JSW, ArcelorMittal Nippon Steel India and government owned SAIL. Indian steel capacity advanced from 109.137mt in 2019-20 to 144.299mt in 2023-24 and capacity utilization during this period rose to a healthy 81%, which is marginally higher than 80% ideal use recommended by Organization for Economic Cooperation and Development (OECD). In sync with capacity growth, Indian steel use rose to 136.291mt in 2023/24 from 100.171mt in 2019/20. The country’s steel demand, according to industry officials, should continue to grow at a conservative 6% CAGR through 2026/27. Capacity across the OECD area saw a fall as the gains in North America and Turkiye were more than offset by declines in the EU and Japan. Steel is responsible for CO2 emissions between 7% and 9% and this makes it imperative to develop a global response to the environmental challenge posed by one industry, according to Dr Edwin Basson, director general of World Steel Association.
A major source of steel related pollution is production through blast furnace-basic oxygen furnace (BF-BOF) route, which has a share of around 70% of global steel output. Pollution emerging from this route is to a large extent due to the use of metallurgical coal from which coke is made as a reductant in BF. As it would be the case, despite its CO2 intensity, most of the new investments proposed in Asia will be in BF-BOF plants. WSA informs the other regions where new steelmaking capacity is emerging, investments are, however, in relatively environment friendly electric arc furnaces (EAFs). WSA says: “Of the new investments announced over the next three years, more than half are now in the relatively low emitting EAF plants, while 42% is in BF-BOF plants.” From exploring ways to replace metallurgical coal by hydrogen to migrating to electricity derived from renewable sources moving away from burning thermal coal, the steel industry is seeing a green transition. DCi
The KINSHOFER C-VHD is often seen in Dutch harbours, loading or unloading ships. Here it is the C60VHD in action.
For more than 50 years now, Kinshofer GmbH has been a leading manufacturer of high-quality attachments for truckmounted cranes and it is now on the way to becoming one of the leading excavator attachment producers worldwide, too. In the last two decades, KINSHOFER has become more and more interesting for the re-handling business, producing large orange peel grabs (P-Series) for excavators with an operating weight of up to 120 tonnes and re-handling clamshell buckets (C-Series) for excavators and carriers with an operating weight from 18 tonnes of up to 100 tonnes.
If you want to handle bulk material on industrial or harbor sites in large amounts, it highly depends on the kind of ‘mass’ you want to grab when choosing the right attachment for the job. Wherever giant cranes, pneumatic vacuum elevators (grain blowers) or conveyors are not available or possible, the classical grabbing devices will always be first choice. Attached to an excavator, their mobility makes them extra attractive. You can get all of these at KINSHOFER’s one-stop-shop.
The sturdy KINSHOFER re-handling clamshell buckets of the C-VHD-series have been developed especially for the
loading and unloading of bulk materials in large amounts. They feature high volume, torsion-resistant shells and thanks to the integrated 360° rotation, the grab can always be positioned precisely. Bearing points have been equipped with specially coated bushings and hardened pins. For especially delicate cargo like grain, there is also the option of closed shells. The shells of the C-VHD-series is driven by vertical hydraulic cylinders with piston rod protection.
An alternative to the clamshell buckets is the KINSHOFER orange peel grab P-series. Sizes range from the smallest P22V for excavators from 16 tonnes operating weight up to the huge P120VHD with a staggering volume of 3,500 litres in the largest variant. Different shell designs — narrow or wide, half or fully closing tines— allow to match the grab to the task. These heavy duty, sturdy grabs are often used to handle scrap, waste or rocks. As the C-series, the orange peel grabs are equipped with a robust 360° rotation. Accurate fittings eliminate tine distortion, the end stops for closing and opening are especially solid. Bolts are reinforced and have a large bearing surface. The hydraulic cylinders that operate the arms are
protected by replaceable piston rod protections.
KINSHOFER sticks strictly to innovation and quality. Thomas Friedrich, President & CEO of the Kinshofer Group, says: “Kinshofer continues its strategy to provide the industry with a ‘one-stop-shop’ solution of outstandingly engineered products to increase efficiency and, more importantly, profitability of our customers.”
Comes in pretty handy when you need to handle bulky material — the P-series orange peel grabs. Here the P51VHD for excavators with up to 50 tonnes operating weight.
JSC “RIKON” stands as the premier manufacturer of heavy lifting equipment in the Baltic region, boasting a legacy that dates back to 1991. With extensive experience, in-house design-engineering office and in-house software development team, “RIKON” is capable of producing a vast array of heavy lifting equipment, but the key and serial products of the company are double jib level luffing cranes and rail mounted gantry container cranes.
During the last two years “RIKON” has not only solidified its position at the forefront of the market in the Baltic region but has also emerged as a prominent supplier on the global stage. The company has successfully designed and delivered cranes for international markets, including Bosnia and Herzegovina, Georgia, Spain, Kazakhstan, and Uzbekistan. The growing reputation of “RIKON”, coupled with positive client feedback, has opened doors for contracts in Slovakia and multiple agreements in Turkey, as well as in Berlin, Germany’s capital.
Entering the German market marks a significant milestone for “RIKON”, as it establishes itself amidst the world’s leading industry competitors. Achievements of “RIKON” are further evidenced by a repeat order from ADIF, the Spanish state railroad
operator, for three A-RMG (automatic gantry cranes). This places RIKON among a select group of companies with expertise in supplying fully automated cranes.
A significant advantage for “RIKON” lies in its robust production complex located at Tvaika Street 68B in Riga, Latvia, set within the port area. This facility allows for comprehensive in-house crane production, ensuring stringent quality control throughout the manufacturing process. Additionally, the presence of a quay facilitates direct shipment of cranes from the factory, presenting a notable advantage for customers.
Recognizing the increasing interest in its products and the growing volume of orders, “RIKON” is actively investing in the expansion and modernization of its manufacturing capabilities, as well as strengthening its brand presence in the global market. Currently, “RIKON” is engaged in several tenders in France, Morocco, Vietnam, and Spain, with a particular focus on projects in France. Having previously supplied a crane for the Grand Port of Marseille in 2021, “RIKON” is now poised to enhance its foothold in the French market.
One of “RIKON’s” key clients is the Riga Central Terminal (RCT), the largest
multifunctional stevedoring company in Latvia, which has been providing terminal and cargo handling services since 1996. With a diverse array of berths, convenient access routes, and an internal broad gauge rail fleet, “RCT” boasts one of the most comprehensive terminal infrastructures in the Baltic States. Specializing in the handling of bulk, general cargo, containers, and Ro-Ro cargo, “RCT” is equipped to manage an extensive range of cargo operations.
To date, “RIKON” has supplied five cranes to “RCT”, originally utilized for coal handling. Over time, however, two RIKON RPS-1600 cranes and one RPS-1680 crane have been successfully repurposed for container handling. Remarkably, despite their initial design for coal operations, “RIKON” cranes now accommodate nearly all container handling at Riga Central Terminal, highlighting the versatility of the double jib level luffing cranes, which can efficiently manage any type of cargo.
In conclusion, “RIKON” is committed not only to cultivating a strong brand, but also to glorify Latvian industry, as proudly stated by the company’s economic director, Alina Deimonta. “RIKON” is one of the few companies capable of designing and manufacturing such huge, yet intelligent machines.
JSC “RIKON” has announced the successful commissioning of a new RMG gantry container crane at “First Dry Port Terminal” LLC in Tashkent, Uzbekistan. With a maximum lifting capacity of 41 tonnes under spreader and a working outreach of seven metres, this new modern crane will enhance container cargo handling in the newly constructed terminal expansion zone.
Operating since 2019, the “First Dry Port Terminal” specializes in complex terminal services and logistics. Spanning an impressive 22 hectares, the terminal features eight railway tracks totalling 5,300 metres, a covered customs warehouse, an open customs area, customs control zones, and efficient loading and unloading facilities.
Strategically located at the crossroads of international transport corridors “East-West” and “North-South”, the terminal serves as a vital logistics hub. It links Europe to Asia, playing a crucial role as a part of historic Silk Road while providing an essential route for goods from India, Southeast Asia, Africa, and the Middle East to Europe, bypassing the need for transit through the Suez Canal.
This dry port is a significant player in the realm of international and domestic multimodal transport, underscoring the strategic importance of developing trade routes in Central Asia. The installation of the “RIKON” crane is set to significantly expedite logistics processes at the terminal, ensuring high performance and reliability. This advancement is anticipated to contribute to the region’s economic development and improve customer service levels.
JSC “RIKON” continues successful serial production of container gantry cranes for ports and container terminals.
A NEW, ON-DEMAND LEARNING PLATFORM FOR AGGREGATE PRODUCERS
Superior Industries, Inc., a US-based manufacturer and global supplier of bulk material processing and handling systems, announces the launch of OptimizeU, an ondemand learning platform for the construction aggregates industry.
Designed to bridge the knowledge gap for a new generation of producers, OptimizeU delivers flexible, cost-effective training, empowering operators to study real-world challenges and drive greater production.
With courses in crushing, screening, washing, conveying, and more, the platform offers 24/7 access to industry expertise, enabling producers to enhance their technical skills, expand product knowledge, and master best practices — all at their own pace.
KEY FEATURES OF OPTIMIZEU:
On-demand access: learn on your v schedule, whether during a break, in the office, or from home. Short, focused courses fit seamlessly into busy workdays.
Practical knowledge: courses address v real-world challenges, from troubleshooting to understanding applic-
ations, with options for beginners and advanced users.
Cost-effective training: OptimizeU v reduces the need for travel and classroom-based workshops, providing a convenient and affordable way to stay up to date.
“OptimizeU was created to meet the needs of today’s aggregate producers,” said Kristen Randall, Training Coordinator at Superior Industries. We understand the value of flexible learning in an industry where time and resources are precious, and our goal is to equip producers with the tools they need to succeed at any experience level.”
OF COURSES
At launch, Superior has a catalogue of 60 courses with plans to expand by 50 new sessions a year.
Cyclone Fundamentals: understand v why cyclones are used, how the technology works, explore models, and gain tips for optimal performance. Conveying vs Trucking: compare v pros, cons, and cost differences of these material handling methods to understand the best fit for your operation.
Understanding Gradations: explore v how gradations impact equipment performance, their role in equipment sizing and selection, and techniques for testing and analysis.
OptimizeU is now available for aggregate producers looking to expand their expertise and improve operational efficiency.
Superior Industries is a deeply-rooted, privately-owned American manufacturing company whose products play a pivotal role in production and transportation of ingredients used to build the world’s infrastructure. Specialties include crushing, screening, washing, and conveying systems, alongside comprehensive parts and services that support robust construction aggregates production from Rock Face to Load Out®
Equipped with one million square feet of manufacturing space and more than 100 engineers, Superior is headquartered in Morris, Minnesota, USA, with four additional production facilities in the United States, plus international manufacturing locations in Canada, Brazil, and Asia.
Several ports across northern and western Australia have transitioned to containerized bulk (CBH), with five new projects recently launched.
CBH was first introduced in Adelaide around 15 years ago, utilizing a Revolver spreader, containers with lids, and a hatchbased dust suppression system, providing a low-loss export method.
Over the past year, the adoption of CBH systems in Australia has surged, transforming traditional bulk export operations in Townsville, Darwin, Broome, Dampier, and Esperance – further solidifying RAM Spreaders’ position at the forefront of the industry.
LOW RISK-NO POLLUTION
One of the key drivers behind the increased adoption of the CBH system is risk reduction.
By sealing containers at the mine and gently loading them at the bottom of a ship’s hatch under a mist barrier, the process eliminates material loss and prevents pollution.
From Townsville along the coast, CBH has been used to handle a diverse range of materials, including copper and phosphate rock in Townsville, iron ore in Darwin, mineral sands in Broome, and sulphur in
Esperance.
The container’s design is adaptable to different cargo types, and the flexibility of the Revolver allows for multiple box heights to accommodate varying material densities.
The system can be used on reachstackers, ship gear, MHC and STS cranes.
With dedicated local support in Australia
and a global aftersales team of 15 specialists, RAM ensures comprehensive product support.
“Our customers appreciate the support they receive. While challenges may arise, we remain committed to standing behind our products, offering global after-sales support, including 24/7 online assistance.” RAM Spreaders Australia.
As the CBH system continues to gain more
traction, RAM has received increasing requests for their use, particularly for rental.
Recently, an urgent inquiry came from Southern Ports in Esperance, where there was a need to load sulphur while adhering to environmental regulations.
The RAM team helped source an existing Revolver from Linx in Port Kembla and provided training and support to the Southern Ports team before and during the load-out. The 12-year old Revolver successfully loaded 30,000 tonnes of sulphur.
The sulphur, which had been stockpiled
at the port since First Quantum Minerals’ announcement last year to put its Ravensthorpe Nickel Mine into care and maintenance, was loaded on the Jersey Spirit
Southern Ports CEO Keith Wilks said that the Port worked closely with FQM to facilitate this unique shipment, “Doing our very best for customers to find ways to facilitate their trade is important to us, even if means doing things differently or finding new solutions from far and wide,” said Wilks.
“Through this process we’ve developed a new export approach for sulphur, taking
advantage of our existing container crane and bringing in connecting rotating container technology from over east.”
“While it’s a little unusual for us to be exporting sulphur, this has shown our capability to export small bulk quantities of all kinds.”
Southern Ports previously imported between 225,000 and 295,000 tonnes of sulphur each year for the Ravensthorpe Nickel Mine. It has been eight years since the last export of sulphur, which relied heavily on ship cranes rather than the Port of Esperance’s crane.
The Port of Esperance is the only regional port in WA to have a container crane. Southern Ports has invested $11.9 million over the past five years into its Berth 2 and container crane assets where it imports sulphur and fertilizer, and exports nickel, copper concentrate and spodumene.
The Jersey Spirit arrived at the Port of Esperance Wednesday 22 January and then departed for the Port of Qingdao.
RAM further stated that it was pleased to support Southern Ports in utilizing one of its existing Revolvers, emphasizing the critical role of product support for endusers, particularly in remote areas such as Western Australia and the Northern Territory, where dependable assistance is essential for customers.
DCi
empowering a new era of efficient and eco-friendly alumina ship-unloader
Recently, two 400tph (tonnes per hour) pneumatic alumina ship-unloaders were successfully delivered. These two shipunloaders were provided by GENMA for the Southeast Asian market, and are manufactured by Rainbow Heavy Machineries.
The market demand for alumina, an indispensable core raw material, for electrolytic aluminum, is growing rapidly.
In response to the characteristics of alumina powder, such as high flowability, a tendency to generate dust, and high abrasiveness, GENMA has conducted thorough analysis of the material properties. A series of innovative designs
have been integrated into the pneumatic alumina ship-unloader to meet the market’s urgent need for efficient and environmentally-friendly unloading solutions for alumina materials.
LEVERAGE HIGH FLOWABILITY TO BOOST CONVEYING EFFICIENCY
The equipment employs adaptive v suction technology independently developed by GENMA, combined with a PLC intelligent control system, to enable an intelligent and smooth material suction process. Additionally, GENMA utilizes the v aerodynamic optimization technology
to help reduce equipment energy consumption during the continuous and stable conveying of materials.
INNOVATIVE PIPELINE DESIGN TACKLES THE PROBLEM OF DUST GENERATION
The GENMA pneumatic alumina ship- v unloader features a well-designed pickup system. The pipeline structure not only enables the flexible operation of the equipment’s boom, but also ensures the pipeline’s tightness, effectively preventing dust escape and minimizing material loss; Moreover, the equipment is provided v with a dust collection device tailored
for alumina materials, effectively capturing fine dust particles and enhancing the equipment’s environmental performance.
The GENMA pneumatic alumina ship-unloader is v equipped with a proprietary intelligent wear reduction mechanism, which significantly reduces friction and thermal effects during material transfer, thereby prolonging the equipment’s service life and ensuring stable and long-term operation; GENMA employs cutting-edge simulation v technologies to apply precise surface reinforcement to core stress-bearing areas of the equipment, significantly enhancing its overall wear resistance. By leveraging these advanced technologies, GENMA’s pneumatic alumina ship-unloader improves both operational efficiency and durability, while also meeting stringent environmental and energy conservation requirements.
Beyond alumina, GENMA provides bespoke pneumatic unloading solutions for a wide range of materials, including grains and cement. By offering professional integrated solutions, GENMA empowers global clients to achieve efficient, environmentally-friendly and energy-efficient material handling in their respective fields.
Bulk-handling conveyors are massive, powerful systems that move tonnes of material per hour in complex networks over long distances, write Jerad Heitzler, Training Manager / Martin Engineering and Todd Swinderman, P.E. and CEO Emeritus / Martin Engineering. Whether the systems are in a mine, cement plant, port, or quarry, their size, speed, and power present the risk of catastrophic injury in the blink of an eye. This makes training essential, no matter what activity is happening around a conveyor.
TRAINING CHALLENGES
Many industries are facing the retirement of workers with expertise and knowledge, leaving them without adequate mentorship.
Conveyor drive motors can be as large as 600HP (450kW), moving belts as fast as 2,000fpm (10mps) (all photos: © 2025 Martin Engineering).
This has both good and bad aspects. Although basic on-the-job training passed down from worker to worker is valuable, it can leave organizations vulnerable to past workers teaching bad habits.
Unless the operations personnel have solid, real-world knowledge in bulk material handling to make educated decisions when addressing problems, bad habits are easily perpetuated. Knowledge needs to help maintenance workers avoid costly and dangerous trial-and-error learning.
Understanding how and why accidents happen is also critical in preventing them from occurring. Having knowledgeable trainers who address the symptoms of problems with workable long-term solutions will reduce unsafe practices and improve efficiency while enhancing profitability.
In many operations, there is a lack of qualified conveyor trainers. Equipment vendors and third-party trainers can be highly effective sources of training. However, with hundreds of companies providing such services, expertise and approaches can vary widely.
Training specialists from equipment manufacturers who offer training programmes like Martin Engineering, focus on overall conveyor performance and safety training. Combining deep industry experience and modern engineering will significantly improve operating decisions, resulting in higher productivity, fewer safety incidents, and reduced unplanned outages.
Qualified teachers should provide a variety of delivery methods based on different learning styles. For example, they should provide good graphics for visual learners, clear documentation for those who learn best by reading, demonstration models, or actual equipment for hands-on learners. These methods should all be designed to increase the probability of measurable positive results.
Organizations that embrace an effective training culture from the top down show significant performance advantages over the competition. This is reflected in safety, productivity, and environmental records, as well as above-industry-average financial returns and share prices.
While many training efforts aim to maximize productivity, improving safety is a key element in achieving this objective. Insufficient safety training can be incredibly costly to an operation. When companies ensure workers have adequate training on particular risks, costs are minimized. Instead of simply teaching workers how to maintain a conveyor system, educators must also help students understand the consequences of not performing adequate maintenance.
With over 80 years of solving bulk handling challenges, the Martin Engineering Foundations™ Training has established itself as the most detailed and comprehensive conveyor belt maintenance and safety training system in the bulk handling industry. Using the Foundations™ textbooks, onsite trainers provide both classroom and hands-on training on the equipment trainees experience daily. The
Some conveyor training providers offer online options that are available 24/7.
free online Martin® Foundations™ Learning Center, accessible by computer, tablet, or smartphone, supports the lessons and is available 24/7. It uses a mix of text, photos, videos, webinars, online events, and live experts available to answer questions.
Martin trainers use the most effective training approach, which examines a plant’s specific conveyor challenges and helps companies run cleaner, safer, and more productive operations by treating the root causes of their problems. When workers and management understand why specific actions are essential and the cascading effects of poorly trained staff, they are more likely to adjust their behaviours and reap the benefits.
Martin Engineering has been a global innovator in the bulk material handling industry for more than 80 years, developing new solutions to common problems and participating in industry organizations to improve safety and productivity. The company’s series of Foundations books is an internationally recognized resource for safety, maintenance and operations training — with more than 22,000 print copies in circulation around the world. The 500+page reference books are available in several languages and have been downloaded thousands of times as free PDFs from the Martin website. Martin Engineering products, sales, service and training are available from 18 factoryowned facilities worldwide, with wholly owned business units in Australia, Brazil, China, Colombia, France, Germany, India, Indonesia, Italy, Malaysia, Mexico, Peru, Spain, South Africa, Turkey, Kazakhstan, the USA and UK. The firm employs more than 1,000 people, approximately 400 of whom hold advanced degrees.
REEL MÖLLER as part of REEL Aluminium, a subsidiary of the globally renowned REEL International group, is at the forefront of the design, development, and implementation of pneumatic conveying and storage solutions. With over 80 years of engineering excellence, the company specializes in providing high-performance conveying systems for fine-grained and mineral bulk materials. Operating across various industries, including cement, aluminium, power, mining, and more, REEL MÖLLER continues to set the benchmark for pneumatic transport efficiency and reliability.
A LEGACY OF INNOVATION IN PNEUMATIC CONVEYING
Pneumatic conveying technology has transformed the bulk materials handling industry by offering an efficient, dust-free, and low-maintenance method of transporting fine-grained materials over long distances. REEL MÖLLER has played a critical role in advancing this technology, continuously improving its designs to enhance efficiency, reduce operational costs, and minimize environmental impact. The company’s expertise is built upon decades of research and development, leading to the creation of several patented technologies that optimize material flow and prevent blockages. These innovations have made REEL MÖLLER a preferred partner for industries that demand
precision, reliability, and high-capacity transport solutions.
COMPREHENSIVE RANGE OF PNEUMATIC CONVEYING SOLUTIONS
REEL MÖLLER offers a diverse portfolio of solutions designed to cater to a wide range of industrial applications. Whether it’s transporting bulk materials within a processing plant or handling large-scale storage and loading operations, the company provides tailored systems that enhance operational efficiency.
1. AIR GRAVITY CONVEYORS
This system uses a controlled stream v of air to move bulk materials smoothly and efficiently across horizontal distances.
Ideal for industries requiring gentle v handling of fragile or aeratable materials.
Offers low energy consumption and v minimal wear and tear on equipment.
2. MÖLLER® MULTI-TURBUFLOW® TRANSPORT SYSTEM
A state-of-the-art dense-phase v conveying system featuring an inner bypass pipe that creates localized turbulence to prevent material blockages.
Provides enhanced efficiency for long- v distance and high-capacity transport. Reduces material degradation, making v
it suitable for industries like aluminium processing and cement manufacturing.
3. MÖLLER® FLUIDFLOW TRANSPORT SYSTEM
Based on super-dense-phase v conveying technology, this system is designed for applications that require the transport of highly abrasive or cohesive materials. Commonly used in industries such as v power generation, metallurgy, and mineral processing.
4. PNEUMATIC ELEVATORS
Designed for vertical conveying of v fine-grained bulk materials. Ensures smooth and efficient lifting of v materials to higher elevations with minimal dust generation.
5. LOADING SYSTEMS
Comprehensive solutions for efficient v loading and unloading of trucks, wagons, and ships. Engineered for high-speed operations, v reducing turnaround times for logistics and supply chain operations.
INDUSTRIES SERVED
REEL MÖLLER’s solutions are widely used across multiple industries, each with its own set of challenges and requirements. The company’s ability to provide customized pneumatic conveying solutions makes it a trusted partner in sectors such as:
Cement, lime, and gypsum: v ensuring the efficient transport of raw materials, clinker, and finished products.
Power industry: facilitating the v handling of fly ash and other combustion by-products in thermal power plants.
Aluminium and metallurgy: v providing advanced transport systems for alumina, bauxite, and other essential materials.
Mining and minerals: supporting the v extraction, processing, and transportation of ores and minerals.
Chemicals and fertilizers: delivering v dust-free and precise conveying solutions for bulk chemical products.
REEL MÖLLER’s history is rooted in innovation. The company’s journey began with Johannes Möller’s pioneering invention of the patented MÖLLER® dry bulk material feed pump, which revolutionized the pneumatic conveying industry. Over the decades, it has continued to push the boundaries of technology, developing advanced conveying systems that improve material flow, increase operational efficiency, and reduce maintenance costs. Today, REEL MÖLLER is recognized as a technological leader, with thousands of successfully implemented systems worldwide.
These systems serve as a testament to the company’s expertise in engineering complete pneumatic conveying and storage solutions.
Sustainability is a key focus for REEL MÖLLER. By offering energy-efficient and dust-free conveying solutions, the company helps industries minimize their environmental footprint. Traditional mechanical conveying systems often result in higher energy consumption, increased wear on components, and greater dust emissions, which can lead to regulatory challenges and higher operational costs.
REEL MÖLLER’s pneumatic conveying solutions are designed to: Reduce energy consumption: v advanced technology optimizes airflow and reduces the need for excessive power input.
our global network of Support and Technology Centres.
Minimize dust emissions: enclosed v systems prevent material spillage and airborne dust, contributing to safer and cleaner working environments. Enhance material efficiency: by v minimizing material loss and degradation, industries can achieve higher yield and cost savings.
To maintain its competitive edge, REEL MÖLLER invests heavily in research and development. The company operates dedicated testing facilities where engineers refine existing products and develop new solutions to meet evolving industrial demands.
Some of the latest advancements in REEL MÖLLER’s pipeline include:
Intelligent monitoring systems: the v integration of IoT-enabled sensors and real-time data analytics to enhance system performance and predictive maintenance.
Automated material handling v solutions: robotics and AI-powered
control systems that improve accuracy and efficiency in bulk material transportation. Next-generation conveying v materials: the development of wearresistant and high-performance materials that extend equipment lifespan and reduce maintenance needs.
REEL MÖLLER under the wing of REEL Aluminium, operates on a global scale, providing solutions to clients in various countries. With a network of service centres and technical experts, the company ensures prompt customer support and maintenance services.
For businesses looking to optimize their bulk material handling processes, REEL MÖLLER offers consulting, engineering, and turnkey project execution services. Whether it’s a new installation or an upgrade to an existing system, the company’s team of specialists works closely with clients to deliver tailor-made solutions.
REEL MÖLLER continues to be a trailblazer in pneumatic conveying technology. With a history of engineering excellence, a strong commitment to sustainability, and a relentless focus on innovation, the company
remains a trusted partner for industries worldwide.
Whether it’s enhancing efficiency, reducing operational costs, or improving environmental compliance, REEL MÖLLER’s cutting-edge solutions are shaping the
future of bulk material handling.
For companies seeking highperformance pneumatic conveying and storage solutions, REEL MÖLLER stands as a name synonymous with quality, reliability, and technological leadership.
Bob Nelson looks at the critical importance of the quality of the rubber in conveyor belts and why, unlike most of their competitors, Netherlands-based Fenner Dunlop Conveyor Belting continues to make its own rubber and invest in more advanced mixing equipment.
Representing around 70% of the volume and some 50% of the raw material cost, the standard of the physical properties of the rubber are the single biggest influence on the length of a belt’s day-today performance, operational lifetime and price. In these times of fierce competition, dominated by Southeast Asian manufacturers, especially China, rubber is seen as the biggest opportunity for a variety of corner-cutting practices. These include using unregulated, low-grade raw materials, bulking agents such as chalk and clay, scrap rubber of highly questionable origin and the substitution of performance-critical polymers such as carbon black with lowgrade versions. Other tactics include reducing the quantity, and often the total omission of key ingredients such as the antioxidants vital to resisting premature
degradation caused by exposure to ozone and ultraviolet light.
Such unscrupulous methods, together with an almost complete disregard for human and environmental safety, enable them to massively undercut the few remaining manufacturers at the quality end of the market, such as the Fenner Dunlop’s of this world. Despite recent announcements of more closures of competitor conveyor belt manufacturing plants in Europe, Fenner refuses to change direction. Instead, it is more committed than ever to further expanding the quality and value gap.
To fully appreciate the importance of the quality of the rubber it is first necessary to have at least a basic appreciation of how it is created. Because of its adaptability, nearly all conveyor belt rubber is synthetic. The creation of rubber compounds is the process where numerous ‘specific task’ chemicals, reinforcements, antioxidants and anti-degradants are mixed together with rubber polymers.
The most common polymers used in conveyor belts are Styrene- Butadiene rubber (SBR) and Nitrile rubber (NBR).
The chemical agents form chains of polymers to form rubber compounds that will ultimately be vulcanized. Vulcanization is the process in which the compounds are chemically converted into a more durable final product by using heat and what are termed as ‘cross-linking agents’ such as sulphur and accelerators. It is a highly scientific process and even more complex when you begin to consider the multitude of physical properties and characteristics that the rubber used in conveyor belts need to possess.
Every type of rubber has to meet a long list of demands, so each compound has to be made according to a very precise recipe. The most basic ability is to resist abrasive wear together with specific minimum requirements in terms of tensile strength, elongation (stretch), hardness, and resistance against tearing. Then of course, there is the ability of the rubber to resist the seriously damaging effects of ground level ozone and ultraviolet light (both sunlight and fluorescent light). As touched on earlier, both of these last two properties require special additives to be an integrated
Creating rubber compounds is a highly complex process.
part of the rubber compound.
These are just the basic requirements. In dry cargo handling there is also a need for ‘specialist’ rubber covers such as resistance against the effects of oil, chemicals, fire, extreme cold (as low as minus 60°C), impact, ripping & tearing and the numerous combinations of those qualities for multi-purpose belts such as oil and fire resistant for example. Last but not least, the rubber needs to be able to form strong, reliable splice joints. Being able to consistently achieve all these requirements during the mixing process so that every individual batch of rubber compound is exactly the same is unbelievably challenging.
Dozens of chemicals and ingredients are used to make the wide variety of rubber compounds. The mixing process is where all of the polymers, chemical additives, carbon black and zinc oxide are mixed together according to the specific recipe for the required rubber type.
For accuracy and consistency, Fenner Dunlop uses a highly advanced computerized, automated mixing carousel that places very precise measurements of each ingredient into polymer-based bags, with one technician likening it to “making cakes that have to taste precisely the same every time”.
It quickly becomes obvious that everyone in the company’s production facility in Drachten is fiercely proud of the fact that Fenner Dunlop is the only remaining European belt manufacturer that continues to make all of its own products using its own production facilities in Europe. This includes the rubber, which is now a rarity due to a growing trend to outsource rubber compound manufacturing, mostly to Southeast Asia, rather than produce it in-house.
The advantage is that specialist rubber compound manufacturers can better minimize costs through mass production,
Precise measurements of each ingredient in polymer-based bags are mixed and blended together
Quality and consistency begins at home — Fenner Dunlop makes all its own rubber.
but the downsides outweigh the perceived advantages. Outsourcing makes it virtually impossible to apply the strict quality process and raw material control disciplines needed to ensure the quality and consistency between batches of rubber produced at different times. Another downside to mass production rather than ‘just in time’ is that some compounds have a ‘best before’ shelf life, so they need to be vulcanized before some important physical characteristics begin to diminish. Unless the large mass-produced volumes are used within a reasonable time-span, they begin to deteriorate.
According to Fenner Dunlop’s Innovation & Sustainability Director, Dr. Michiel Eijpe, outsourcing rubber production is not an option. “It is essential that we have total control from beginning to end, not only to consistently achieve identical high qualities and properties but also to comply with environmental regulation, which we believe is extremely important”.
It is an inescapable reality that to make some rubber compounds it is necessary to use chemicals that are hazardous in their own right. Fortunately, at least as far as Europe is concerned, there are very strong regulations in place to protect humans and the environment such as REACH (Registration, Evaluation and Authorisation
of Chemical substances) regulation EC 1907/2006 and EU Regulation No. 2019/1021 concerning the use of persistent organic pollutants (POP’s).
Manufacturers located outside of EU/EEA member states are not of course, subject to REACH and POP’s regulations so they are free to use unregulated raw materials, which cost much less compared to their regulated counterparts, even though they may be entirely prohibited or at least have strict usage limitations within the European community. Sad to say that it is also true that even most European belt suppliers ignore these regulations because doing so creates an extremely significant price advantage.
Fenner Dunlop is certainly committed to its policy of making everything itself, recently proven by its investment of some €2.4 million in new machinery in its mixing department. “The primary reasons why such investment was needed revolves around quality, safety and the environment”, explains Dr. Eijpe. “Firstly, we wanted to achieve even better control over the mixing process, especially when processing some of the more difficult materials we are now having to use. This is
Dr. Michiel Eijpe. Fenner Dunlop’s Innovation & Sustainability Director.
a result of the need to find alternatives to materials that we can no longer source from previous suppliers, for example due to the Russia–Ukraine conflict. It is, of course, essential that these alternatives have the same or higher quality properties as we have used before.
“REACH and POP’s regulation compliance also means that we need to find processing solutions for the substitute chemicals that replace those that become banned or have usage limitations placed upon them. There is also the question of safety because new ISO standards relating
to the operational safety of machinery are being introduced. When they are implemented, our new mixing machines will instantly be compliant”.
There is no question that the quality of the rubber has the biggest part to play in terms of performance, longevity and human and environmental safety. Unfortunately, it also provides the greatest temptation for manufacturers to sacrifice quality in order to create an even wider price gap. However, for those importers who place price ahead of quality and longevity, there will be an even bigger price to pay because ultimately the big prize for the ‘market saturation’ tactics employed by Southeast Asian manufacturers is that when their competitors have been forced out of business, the market is at their mercy. Not only will they have lost their challengers in terms of quality standards, they will also be free to charge what they like, which we have seen happen in many other industries.
Fortunately, Fenner Dunlop certainly has no intention of becoming their next victim. By taking a quality-led stance, it is at least providing the end-user market with a choice. Long may that continue.
Bob Nelson
In today’s competitive industrial landscape, efficiency and innovation are essential to maintaining a prominent market position. Recognizing this reality, GBS Group International and Emotron have forged a strategic alliance aimed at revolutionizing the bulk material transportation sector. This collaboration focuses on integrating advanced technological solutions that optimize material handling operations, providing companies with robust tools to face present and future challenges.
The core of this alliance lies in the synergy between GBS Group International’s expertise in transport systems and Emotron’s advanced motor control technology. The objective is to provide specialized speed control solutions for conveyor belts, essential components in bulk material handling. The incorporation of Emotron’s variable frequency drives and soft starters into GBS Group’s solutions seeks to optimize material flow, reduce mechanical wear, and improve energy efficiency. These technologies allow precise control of the speed and start-up of the belts, adapting to the specific needs of each operation and ensuring safer and more efficient material handling.
In addition to speed control, the alliance focuses on developing advanced monitoring systems for conveyor belts. By establishing robust communication protocols, it is
possible to monitor the status and performance of the belts in real-time, anticipate failures, and schedule preventive maintenance. This continuous monitoring capability not only increases equipment lifespan but also minimizes downtime and optimizes productivity in bulk material handling operations.
Emotron possesses vast experience in the bulk material handling industry, backed by years of dedication to developing efficient and reliable solutions for electric motor control. Its knowledge and expertise enable them to maximize the
production of industrial equipment, providing efficient and reliable control of electric motors.
This experience translates into Emotron’s ability to offer solutions that ensure efficiency and reliability in equipment such as pumps, fans, cranes, mixers, mills, centrifuges, and conveyors.
The company’s variable frequency drives offer high precision in dynamic applications, which is crucial in environments where precision and adaptability are essential for operational success.
The collaboration between GBS Group
International and Emotron is enriched by the incorporation of a wide range of highquality products and services that Emotron offers:
Variable Frequency Drives (VFD): Designed for dynamic applications, Emotron’s VFX drives provide direct torque control, precise speed control, and efficient vector braking. They are ideal for reliable control of equipment such as cranes, crushers, and centrifuges, ensuring optimal performance and extended equipment lifespan.
Soft Starters: Emotron’s TSA soft starter range allows motors to start smoothly and controlled, reducing mechanical and electrical stress on systems. This translates into reduced maintenance costs and greater operational reliability.
Electronic torque limiters: the Emotron M20 electronic torque limiter protects equipment such as pumps from damage and downtime. By immediately detecting overloads and underloads, it allows preventive measures to be taken that decrease maintenance costs and increase system reliability.
Services and Technical Support: GBS Group International and Emotron offer a wide range of after-sales services, including professional repairs, replacement equipment, global technical assistance, and personalized training for sales and maintenance personnel. This support network ensures that customers can operate their systems with confidence and efficiency.
GBS Group International, renowned for its expertise in designing, manufacturing, and assembling high-quality conveyor belts, joins forces with Emotron, an expert in electric motor control solutions. This collaboration seeks to integrate advanced technologies into transport systems, improving operational efficiency and the reliability of industrial processes.
The incorporation of Emotron’s solutions into GBS’s conveyor belts offers multiple advantages:
Energy efficiency: Emotron’s variable v frequency drives and soft starters allow precise control of motor speed and torque, reducing energy consumption and operational costs. Extended equipment lifespan: by v minimizing start-up intensities and mechanical stress, the wear of conveyor belts and their components is reduced, prolonging their durability. Operational reliability: Emotron’s v solutions ensure efficient and reliable control, ensuring that the amount of material entering and exiting the
process is appropriate, which is crucial to maintaining continuity and quality in industrial operations.
With a solid track record in the industrial sector, Emotron has specialized in developing complete drive systems, based on a range of standard products such as variable speed drives and soft starters. Its focus on energy efficiency and reliability has positioned the company as a strategic partner for various industries, including mining, water treatment, and power generation.
The synergy between GBS Group International and Emotron is poised to revolutionize the conveyor belt market by introducing technologies that improve energy efficiency, reliability, and productivity of material transport systems. Customers adopting these solutions will benefit from more efficient operations, reduced costs, and greater competitiveness in their respective markets.
This strategic alliance represents a significant opportunity for companies seeking to optimize their material handling
processes, backed by the experience and innovation that GBS International Group and Emotron bring to the market.
The strategic alliance between GBS Group International and Emotron represents a significant milestone in the evolution of the conveyor belt market. By combining the expertise and innovation of both companies, solutions are offered that not only optimize operational efficiency but also promote sustainability and competitiveness in various industries.
Business leaders seeking to stay at the forefront should consider how these integrated technologies can transform their operations, reducing costs and improving productivity. This collaboration not only responds to current market demands but also anticipates future needs, setting new standards in material handling.
In an ever-changing business environment, the ability to adapt and innovate is crucial. The synergy between GBS and Emotron offers companies the opportunity to reinvent their processes, ensuring sustainable growth and a prominent position in the global market.
BRAKEMATIC® is an innovative brake control system from EMG Automation that ensures the safe, load-independent and controlled braking of conveyor belts, cranes and ladle transfer trolleys.
When conveyor systems are switched off and with asynchronous braking speeds, material spillages can arise, which in turn lead to costly downtime.
A power failure causes the conveyor belt to brake suddenly, which can result in serious damage such as belt tears, leading to lengthy downtimes and high costs.
EMG BRAKEMATIC and EMG BRAKEMATIC advanced are solutions to these problems, guaranteeing the safe and controlled braking of conveyor systems in any situation.
BRAKEMATIC® advanced is a precise, electronic control for load-independent braking by means of an ELDRO® system or system from other brake manufacturers.
The system operator specifies a time interval within which the system should come to a standstill.
When braking operation is initiated, the system adjusts the brake force by analysing the actual and target values in real time, in order to brake the belt independently of the load.
If BRAKEMATIC® is additionally equipped with a battery, it can also brake the conveyor system in a controlled manner in the event of a power failure —
thereby preventing associated damage.
With the EMG BRAKEMATIC® system, the conveyor belt, a crane jib or a ladle transfer trolley can be braked safely and in a controlled manner by an operator using a joystick or pedal.
Multiple brakes can be controlled v using a single BRAKEMATIC®
Existing brakes can be upgraded with a v BRAKEMATIC® without restriction.
CONTICLEAN: ONE SOLUTION, NUMEROUS ADVANTAGES
ContiTech offers a non-stick solution that helps prevent material from sticking to belts and thus solves several problems at once. What benefits does it provide? Who can profit from this? What are customers’ experiences with this product?
Dispersion of particles into the environment, carryback on the conveyor return run, costs for cleaning belts: Wherever material is transported on conveyors, there are many areas with room for improvement. “With ContiClean, we provide solutions enabling superior material release characteristics for everything from cement to limestone,” says Chris Marchant, Global Product Manager at ContiTech. “These ready-touse conveyor belts not only help customers reduce the costs associated with cleaning belts and systems, they can also prevent belt damage and improve safety outcomes.”
THE FINER THE MATERIAL …
ContiClean is especially useful for companies that transport very fine material, as Marchant explains: “The finer the material, the greater the difficulty with release when transferring it from one conveyor system to the next. Since the base material after mining, crushing and additives is a fine powder, ContiClean provides a useful solution especially for customers operating in the cement sector. If the system happens to be completely exposed and it rains, it is even more difficult to remove the damp or wet powder.”
INCREASING DEMAND AND SUSTAINABILITY AWARENESS
Given the strong growth in demand expected for cement and concrete, increased sustainability, efficiency, safety and profitability will play an important role in the coming years. According to current forecasts, demand will increase by an average of two to three percent per year, mainly due to increasing urbanization and investments in infrastructure. Based on these expectations, cement consumption will have almost doubled by 2050 compared to today.
“ContiClean supports the production of cement and other materials in being more sustainable through a reduction of dust-borne air emissions, pollution and waste,” Marchant continues. “In addition to increased efficiency, the positive impact
Conveyor belts installed at the start of cement production must be able to perform in extreme conditions.
on the environment is of course a feature that helps companies operating in the cement industry reach their sustainability goals. Especially as the awareness for this topic is increasing.”
Standard belt covers and scraper systems may not provide sufficient material release, which can then lead to many adverse effects for production. “Adverse effects resulting from carryback issues include material buildup on pulleys, idlers and belt covers,” explains Marchant. “Any one of these issues can lead to increased cover abrasion, belt alignment problems, belt or system damage and significant increases in the cost for cleanup. All of these contribute to safety and environmental hazards.”
With ContiClean, customers can benefit from increased material transfer, reduced material buildup on pulleys and idlers, increased belt cover and scraper life, reduced maintenance and safety issues, less downtime for maintenance issues, lower operating costs, increased profitability – the list of benefits is a long one.
The feedback ContiTech receives from its customers is consistently positive, as Marchant points out: “ContiClean is a global solution, with all regions reporting favourable customer feedback. A system installed at a cement plant located in the USA, for example, reduced their carryback issue by 95%. Another reported reducing their material buildup on the walkway below by 75%. The operator at this plant is incredibly happy with the results. Prior to the introduction of ContiClean, this was a major issue for this site.”
Another customer in Chile that conveys
material with sulphuric acid reported a serious problem with material accumulating throughout the system structure. “The customer’s previous experience with a competitor solution was unsuccessful,” says Marchant. “ContiClean’s non-stick release characteristic is present throughout the carry side cover thickness. For this customer, we helped them not only to overcome their material accumulation issue but also to double their conveyor belt service life.”
SUSTAINABILITY AMBITION
The benefits of ContiClean for customers are also in line with the most important strategic goals established by Continental. By 2050 at the latest, the technology company and its supplier partners strive for carbon neutrality along the entire value chain.
Alongside Emission-Free Mobility and Industry, Circular Economy, and Responsible Value Chain, Carbon Neutrality is one of four major pillars we are building on today and will continue to build on in the future,” emphasizes Marchant. “With these efforts, we are following our sustainability ambition — providing the framework to turn change into opportunities.”
TOUGH MATERIALS TO TACKLE TOUGH OPERATING CONDITIONS: CONVEYOR BELTS BY CONTINENTAL
Continental is the most comprehensive, high-performance conveyor belt systems provider in the world, offering a wide range of products for cement and aggregate applications.
The extremely tough operating
conditions that prevail in the cement industry mean that a variety of demands are placed upon the conveyor belts used. Thanks to Continental’s many years of experience in this special field as well as its deep material competence and broad R&D footprint, the company from Germany can offer complete solutions for all phases of cement production. The range of products and services includes textile and steel cord conveyor belts, special purpose conveyor belts, service materials, digital solutions and all related service activities.
A JOURNEY THROUGH THE CEMENT PRODUCTION PROCESS WITH CONTINENTAL CONVEYING SOLUTIONS
Quarry and moving materials: the v conveyor belts installed at the start of cement production must be able to perform in extreme conditions. After the limestone blocks have been crushed, they are carried by a conveyor belt to their next destination. Loading point impact damage can be a major cause of belt failure at this point. This is where belts must be capable of handling heavy impacts and heavy lump weights. Continental’s Fortress XP and Conti Titan textile belts are designed specifically to handle this kind of heavy impact and wear conditions. These rugged, fabric-reinforced conveyor belts withstand high-abuse applications, delivering up to three times longer life. The special fabric designs of these belts enable high transverse tear strength and minimize tears that result from material punctures.
The crushed limestone is in the next v step transported with conveyor belts
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which have to cover long distances.
Continental’s Flexsteel steelcord belts are designed to deliver high-tension capabilities to allow for extremely long centres, exceptionally high lifts and multiple horizontal curves.
ContiPipe conveyor belts are another v alternative for transporting crushed limestone. The conveyor belt is equipped with fabric or steel cable tension members. At the loading point, the belt is troughed, and the materials are fed onto the belt in the conventional manner. The enclosed design of this conveyor belt prevents dust and dirt from escaping and protects the materials from rain, snow and wind.
In-plant transportation: during the v cement production process, especially, the problem of caking and contamination of the conveyor belt cover occurs more frequently.
Continental’s innovative ContiClean rubber compound is helping to prevent materials, like cement, from sticking to belts and keeping the conveyor system profitable and running while reducing cleaning costs and extending the belt lifetime.
Burning process — clinker burning: v during the burning process in a cement plant, energy sources such as coal and oil are used to generate energy. In conventional conveyor belts, the cover absorbs the liquids, and this means the conveyor belt may swell after some time. Continental’s Gold belt qualities offers different levels of oil resistance (Classic, Plus and Extreme), dependent
of the material conveyed, for this stage of production.
Another environment-friendly v solution to transport bulk materials is Continental’s Sicon conveyor belt, which consists of highly flexible rubber capable of forming a pear-shaped bag. As the profiles are arranged above one another, the belt is closed to form a dust-tight bag. Sicon conveyor moves material over demanding topographical conditions and can negotiate 180° curves with a radius of less than one meter.
After the burning process: v Continental’s Solar-Shield belt qualities (Classic, Plus and Extreme) offer different levels of heat-resistance. Solar-Shield Extreme is Continental’s best solution for hot clinker as its covers are ultra-heat-resistant and able to withstand peak temperatures up to 400°C, thus guaranteeing protection of the belt’s tension member.
Packaging and storing: in a vertical v conveying configuration, Flexowell corrugated sidewall belts have an extremely low space requirement. Flexowell belts are flexible in a longitudinal direction while still featuring high transverse rigidity, which is required for steep and vertical application.
In recent years, Continental has been making fast-paced steps towards becoming a full-service and a solutions supplier to the
cement and clinker industry, instead of focusing on products only. This includes planning and commissioning, technical advice, training, digital monitoring, and onsite maintenance. All of these designed to increase longevity, prevent workflow interruptions and thus increase efficiency of a conveyor operation.
In this course, Continental has in recent years acquired the Swedish companies Backes Transportbandservice (2022), Vulk & Montage (2022), Norr Vulk AB (2022) and Vertech (2023). In Sweden, Continental offers an innovative pay-per-tonne model which includes predictive maintenance, process analytics, or several innovative surveillance methods. Here, Continental is not paid for a product, but rewarded for keeping the conveying process running.
Continental’s corporate philosophy is to act in an environmentally friendly and quality conscious way. The company has introduced its ambitious comprehensive sustainability goals in 2020 focusing on the four pillars carbon neutrality, emissionsfree industries, circular economy, responsible value-chain. In this context the Continental material experts across the globe continually work to optimize products by developing energy-optimized and environmentally friendly conveyor belts. One example for this is Continental’s Eco Series of unique, energy-optimized rubber compounds. By reducing rolling resistance caused by indentation on the conveyor the energy required for raw material transport is reduced by up to 30%.
KOCH Solutions stands at the vanguard of material handling, driving progress with over three centuries of combined expertise and a global portfolio boasting 10,000 projects. At KOCH Solutions, we are redefining material handling excellence with our advanced stockyard systems. Meticulously engineered to cater to the dynamic demands of high-capacity operations, our solutions stand out for their modular innovation and seamless integration into existing workflows. Crafted from a blend of tried-and-tested components, each system we devise is a testament to our commitment to tailor-made efficiency. We don't just provide equipment; we deliver comprehensive, turnkey solutions that resonate with your unique specifications, ensuring operational effectiveness paired with economical investment and operating costs. Our ethos is to forge a path of progress in material handling that aligns with your vision of growth and efficiency.
Dust emissions and material spillage present ongoing challenges in the handling of dry bulk materials, particularly in industries such as cement and gypsum production. These issues not only pose environmental, health, and safety risks but also lead to increased maintenance efforts and production downtime. ScrapeTec offers an innovative solution with its contact-free AirScrape® conveyor belt skirting system and the highly efficient DustScrape filtration technology.
Conveyor transfer points in cement and gypsum plants are notorious for dust generation and material loss. Traditional side seals often fail due to wear and inefficient sealing. The AirScrape® system, however, operates without direct contact with the belt, instead using the Venturi effect to channel fine dust particles back into the material flow. Meanwhile, the DustScrape system enables controlled air release via a specialized filter cloth, ensuring minimal dust escape while maintaining a clean environment. Following installation, plants can achieve
up to a 98% reduction in dust emissions and material loss. Additional benefits include reduced belt damage, lower maintenance costs, and fewer production downtimes. The DustScrape filtration system not only significantly cuts dust emissions but also improves cost efficiency and workplace conditions.
The DustScrape system is particularly effective at mitigating dust emissions at conveyor transfer points. In enclosed transfer zones, where pressure buildup can create dust clouds, the system facilitates effective pressure relief, ensuring cleaner operations.
A unique feature of the DustScrape system is its ability to enhance the performance of existing dust extraction systems. When combined with the AirScrape, it improves overall efficiency by at least 50%, leading to further energy savings and reduced maintenance expenses.
As dust emission regulations become increasingly stringent, ScrapeTec is witnessing growing demand for its solutions. Companies worldwide are
investing in these technologies to maintain compliance, improve operational efficiency, and create safer work environments.
A cement producer at the Port of Brisbane faced severe operational issues due to: excessive dust emissions, creating v major occupational health and safety (OHS) concerns; frequent material spillage; v conveyor belt sagging and inadequate v support; and the need to minimize production v shutdowns.
The company specializes in unloading bulk cement materials, which are later packed into 20kg bags or loaded into trucks for construction and road development projects. During a site inspection, ScrapeTec’s technical representative identified that the existing chute sealing system, consisting of external clamping and standard skirting, was insufficient to contain dust and spillage. These inefficiencies led to zero visibility in a 70-metre-long conveyor tunnel, making maintenance and monitoring extremely difficult.
Management recognized that material spillage was impacting profitability due to additional cleanup costs and the need for frequent dust extraction. Dust emissions also posed significant hazards to workers and the surrounding environment, requiring urgent mitigation.
ScrapeTec installed the AirScrape® system at the transfer point, achieving: a 98% reduction in dust emissions and v material spillage; no belt damage, no further v adjustments required, and minimal maintenance; performance exceeding expectations; v and opportunities to upgrade additional v transfer points.
Initially introduced on a trial basis in 2020, the AirScrape® installation proved so effective that the operator proceeded with a second-phase upgrade. This phase included installing TailScrape® and the ST-Containment Seal to provide additional sealing and dust control.
To maximize AirScrape® performance,
the SureSupport Belt Support System was implemented, ensuring a smooth, level belt surface that allowed AirScrape® lamellas to maintain their optimal position without belt contact. Working in synergy, TailScrape® provided outstanding rear sealing, while the ST-Containment Seal acted as a first line of defence against dust and spillage.
Following the upgrades, site maintenance teams reported vastly improved visibility along the conveyor system, enhancing operational oversight and efficiency. The site manager commented, “The Essential AIR Seal Dust Containment Solution is a vast improvement over our initial setup, with no belt damage and no ongoing maintenance required.”
Encouraged by the success of the AirScrape® system, the operator plans to implement similar upgrades across five additional transfer points, covering the entire conveyor stream from ship unloading to stockpile storage.
This strategic decision ensures longterm benefits, including reduced belt wear, lower maintenance costs, and enhanced material containment.
As industries continue to face increasing regulatory and operational challenges related to dust emissions, innovative solutions like AirScrape® and DustScrape are proving essential for cleaner, more efficient bulk material handling.
Maintenance free bearing Unique 360 degree
Direct stearing without friction
Reacts to slightest belt misalignments
Works perfectly with reversible belts
At the pulp mill of international fibre manufacturer Lenzing in central Austria, uninterrupted material transport is essential for a smooth production process. Conveyor belts in particular, which transport moist wood chips among other things, have to withstand extreme loads in order to avoid breakdowns and downtimes. As a leading international supplier of conveyor technology and wear protection solutions, REMA TIP TOP supported the plant with a tailor-made solution for two critical conveyor belts with a total length of over 200 metres.
Two profiled, oil- and grease-resistant EP400/3 4+2 conveyor belts were installed at a height of 40 metres. These are equipped with 3mm high nubs that provide a non-slip surface — a key feature for the safe and efficient transport of the moist wood chips, which have a water content of around 40%. The special design of the conveyor belts ensures that they can withstand the extreme conditions of wood processing without swelling or losing strength. This is mainly due to the wood components cellulose, lignin and hemicellulose in combination with moisture, which quickly makes conventional conveyor belts unusable.
“In pulp production, the smooth running of the conveying processes is crucial. With our comprehensive maintenance service, we support Lenzing in optimizing planned maintenance intervals and minimizing unplanned downtimes,” explains Wolfgang Tronegger, Managing Director of REMA TIP TOP Industrie GmbH. “Like us, Lenzing has high
quality and safety standards, which is the basis for a longterm co-operation. The work was carried out by an experienced three-man installation team and completed in the agreed time and quality.
By providing durable conveying solutions, REMA TIP TOP helps to ensure that production in the pulp mill can be planned in advance and carried out largely without interruption. This increases Lenzing’s operational reliability. “This type of partnership cooperation shows how we can offer our customers added value as a reliable service partner — from consulting and planning to precise implementation and long-term support,” continues Wolfgang Tronegger.
Precision required: installation of the conveyor belt with a crane to the installation site at a height of 40m.
TOP colleagues, and the number of technicians employed is also steadily increasing.
This type of proactive component maintenance is no longer standard practice everywhere.
“Especially in a difficult economic situation in the construction and concrete industry, such as we have been in for the past two years, the repair aspect is becoming increasingly important,” says Wolfgang Tronegger. “Many customers find it difficult to carry out the necessary maintenance work with their own personnel. They are therefore concentrating more and more on their core competencies and reacting quickly to ‘unexpected’ damage. REMA TIP TOP Industrie GmbH is thus continuously expanding its own service in close co-operation with its German REMA TIP
REMA TIP TOP is a globally operating system provider of services and products in the field of conveying and treatment technology as well as tire repair. The company has a global service network and offers a wide range of rubber products, linings and coatings for both the industrial and automotive sectors. Over almost a hundred years, the company has built up unique expertise in materials development and industrial services and is active in the belting, material processing, surface protection and automotive sectors. At the end of the 2023 financial year, REMA TIP TOP generated sales of about more than €1.4 billion. Worldwide the company employs 9,000 employees and has more than 200 subsidiaries and associated companies — including well-known brands such as Dunlop Belting Products South Africa and Asplit.
aterial blockages can bring your operation to a standstill—costing you time and money. Whether preventing bridging in hoppers, eliminating buildup along chutes, or maintaining steady movement at transfer points, Martin Engineering’s MM Series electric vibrators ensure uninterrupted, consistent construction, engineered for continuous duty, and backed by an industry-leading 3-year guarantee. MM
Multiple transfer conveyors feeding bulk product into large landfill area.
Bulk cargo handling is a cornerstone of global trade, ensuring the efficient movement of essential materials across industries. At the heart of this process,
conveyors play a critical role in maintaining seamless supply chains at ports, storage facilities, and mining operations. Mobile Conveying Services Pty Ltd (MCS) has
revolutionized bulk cargo logistics by providing specialized mobile conveyor systems that enhance efficiency, adaptability, and reliability.
In today’s fast-paced industrial landscape, efficient and reliable material handling is paramount to sustaining high-volume production and logistics. JSC “CONVIR”, is proud to be at the forefront of designing, producing, and delivering state-of-the-art bulk conveyor solutions that serve a diverse range of industries — from bustling ports and expansive quarries to dynamic mining operations and modern food processing facilities.
Based in Kaunas, Lithuania, JSC “CONVIR” may be a relatively young name in the market, but its team brings nearly 20 years of experience in the material handling sector. This wealth of expertise empowers it to create innovative, custom-designed solutions that not only meet but exceed the rigorous demands of handling dry bulk products. The company’s passion for engineering excellence, combined with a commitment to reliability, has positioned it as a trusted partner for businesses around the globe.
At the heart of the JSC “CONVIR” product portfolio is a wide range of conveyor systems that are designed to optimize the transport of bulk materials. The company manufactures both stationary and mobile conveyors, each tailored to address the unique challenges of various industrial environments. Each system is developed with a focus on durability, efficiency, and adaptability, ensuring that our equipment can meet the specific needs of diverse industries such as mining & metallurgy, quarries, recycling, agriculture, wood & paper, and the sugar & food industry.
Dry bulk materials come in many forms — from ores and aggregates to processed
food ingredients and recycled waste. JSC “CONVIR” conveyors are engineered to handle a broad spectrum of commodities with precision and care. For instance: Ports and terminals: in these high- v throughput environments, the company’s conveyors are designed to support the rapid loading and
unloading of cargo, contributing to smoother operations and enhanced productivity.
Quarries and mining operations: the v robust construction of JSC “CONVIR”‘s equipment ensures that even the most abrasive materials are transported safely and efficiently, reducing downtime and maintenance costs.
Wood & paper and sugar & food v industries: by providing tailored solutions that accommodate the specific properties of these materials, JSC “CONVIR” helps maintain product integrity and reduce contamination risks.
Recycling and Agriculture: JSC v “CONVIR”‘s systems adapt to the variable nature of recycled and agricultural materials, ensuring consistent performance regardless of the material’s density or moisture content.
RADIAL TRUCK UNLOADER – CONVIR MTTU2200/20: UNLEASHING CONTINUOUS EFFICIENCY
Among high-performance solutions, the Convir MTTU2200/20 radial truck unloader stands out as an exceptionally practical and innovative product designed for modern bulk handling. This state-ofthe-art system is engineered to enable the continuous unloading of trucks directly into train wagons or barges, streamlining operations and significantly boosting throughput. The unique radial design of the MTTU2200/20 ensures a smooth, uninterrupted flow of material, which minimizes downtime and optimizes productivity. Whether dealing with coal, aggregates, mulch, grain, scrap metal, or virtually any bulk commodity, this truck unloader adapts effortlessly to the demands of various industrial environments — be it ports, mining operations, or largescale processing facilities. Constructed with durability in mind, the radial truck unloader is built to withstand the rigours of harsh operational settings while maintaining high performance. Its robust construction and ease of integration into existing loading infrastructures make it a cost-effective solution that not only meets but exceeds modern industry standards. This innovative product is a testament to the “CONVIR” commitment to providing reliable, efficient, and versatile bulk handling solutions that empower its clients to achieve operational excellence.
Staying competitive in today’s market means constantly pushing the boundaries of technology. At “CONVIR”, innovation is woven into every stage of the product development process. The company’s engineering team leverages the latest technologies to enhance the performance, energy efficiency, and durability of its conveyors. Some of the “CONVIR recent technological developments include:
Advanced control systems: the v company’s conveyors now feature integrated control solutions that allow for real-time monitoring and adjustments. This not only optimizes performance but also enhances safety and minimizes the risk of downtime.
Modular designs: to meet the v evolving demands of bulk handling, JSC “CONVIR” has introduced modular designs that enable quick assembly, easy maintenance, and scalable solutions for clients with growing needs.
Enhanced material handling: using v high-quality components and state-of-
the-art fabrication techniques, our conveyors are engineered to handle even the most challenging bulk products while ensuring minimal wear and tear.
As global demand for efficient dry bulk handling continues to grow, “CONVIR” remains dedicated to advancing its technologies and expanding its market presence. It is constantly exploring new methods to improve its product offerings and stay ahead of industry trends. Whether it’s through the integration of smart automation or the development of nextgeneration conveyor systems, JSC “CONVIR”‘s goal is to empower businesses worldwide with reliable and innovative material handling solutions.
In an industry where millions of tonnes of dry bulk products are transported annually, having a reliable and efficient conveyor system is critical. JSC “CONVIR”, is proud to contribute to the global material handling landscape by offering equipment that combines innovative design, robust construction, and comprehensive support. The company will continue to drive efficiency and excellence in dry bulk handling worldwide.
Motor Driven Reels
• Monospiral and Level-Wind configurations
• Rugged and dependable magnetic coupler for dusty environments
Cable Festoon
• Corrosion-resistant, long-life rollers; precision sealed bearings
• Systems customized for the application
• Preassembled option, for easy installation
Slip Rings
• Allow infinite rotation
• Combined power, control and media (water, air, oil, vacuum, other)
• Available with ATEX and SIL 3 certification
Conductix-Wampfler has one critical mission: To keep your bulk material handling operations running 24 / 7 / 365. You need proven, worryfree energy solutions - and Conductix-Wampfler has them. Our systems provide reliable electric power and water to stacker/reclaimers, barge and ship loaders/unloaders, bulk conveyors, tripper systems, and gantry cranes. Conductix-Wampfler systems are rugged, low maintenance, and timetested in tough, dusty environments. All products are backed by the largest sales and service network worldwide!
www.conductix.com
TAKRAF Group secured a major contract to design and supply a conveying system for Compañía Minera Doña Inés de Collahuasi SCM’s Ujina growth project.
TAKRAF Group (‘TAKRAF’) has announced the award of a contract to engineer and supply the conveying system (CV-8001, CV-8002 and CV-8003) for Minera Collahuasi’s Ujina growth project in Chile.
The main objective of the Ujina growth project is to increase the capacity of the concentrator plant.
The Collahuasi mine is located at an impressive elevation of 4,535m above sea level and has been in operation since 2003. It is one of the largest copper producers in the world, one of the largest copper deposits globally.
TAKRAF’s scope of supply for this brownfield project comprises the design and supply of three advanced conveyors This system will seamlessly connect a relocated crushing station to the mine’s existing conveyor network, ensuring efficient material handling under challenging operational conditions.
“We are particularly proud and would like to highlight the client’s continued interest in TAKRAF equipment, 20 years after the initial supply. This is a testament to the quality and excellence
TAKRAF’s scope of supply: conveyor system (CV-8001, CV-8002, CV-8003) to connect an existing, relocated crushing station to an existing conveyor system.
Innovation out of tradition — it pays to talk to a specialist
of our colleagues in designing and delivering exceptional equipment that ensures reliable operation, a fundamental requirement for any mining equipment.”, says Andres Costa, Managing Director of TAKRAF Chile and Peru.
TAKRAF extends its gratitude to the client for their trust and to its teams in Germany and Chile for their exceptional collaboration and technical expertise. This achievement reaffirms TAKRAF’s position as a leading provider of innovative solutions in mining and material handling.
TAKRAF Group, through its established and well-known brands, TAKRAF and DELKOR, provides innovative technological solutions to the mining and associated
industries. It leverages its experience, acquired over more than a century, to provide equipment, systems and services that best satisfy its clients’ mining, comminution, material handling, liquid/solid separation and beneficiation requirements. Owners
and operators around the world trust TAKRAF’ engineered solutions to lower the total cost of ownership and reduce environmental impact by improving efficiency with safe and reliable equipment. TAKRAF Group is a trusted supplier of sustainable solutions backed by expert service.
TAKRAF crushing station and TAKRAF conveyor for the discharged material delivered in 2003.
Conveyor belts are crucial components in mining and heavy aggregate handling operations, where efficiency and reliability are paramount. However, these systems often encounter significant challenges, particularly in the loading zones where the impact of falling materials can cause severe belt damage. Tru-Trac’s EXHD Dynamic Impact Idler Bed offers a robust solution designed to protect belts and enhance system reliability in the most demanding applications.
COO of Tru-Trac, Shaun Blumberg
unpacks the design, benefits and broader impact control capabilities of Tru-Trac’s innovative solution.
Blumberg says the challenge of managing impact control in loading zones is a significant one for all materials handling operations. “These transfer zones are the points where materials are introduced onto the belt from chutes, often from considerable heights ranging from two metres up to ten metres. The force of this impact can lead to various issues including belt damage, material spillage and belt
Built for durability, Tru-Trac’s EXHD Impact Idler Bed tackles the toughest conditions.
misalignment. Insufficient support and impact control ultimately results in frequent maintenance needs, increased downtime and higher operational costs.”
“Traditional impact rollers, while commonly used due to their low cost, often provide inadequate shock absorption particularly in high-drop applications,” he continues. “Furthermore, poorly designed chutes and under-specified impact beds can worsen the problem.”
It is a known fact that improperly engineered loading zones that fail to
distribute material evenly or align with the belt’s trajectory create uneven wear, and this significantly increases the likelihood of belt damage.
According to Blumberg, Tru-Trac’s EXHD Dynamic Impact Idler Bed represents a unique and significant advancement in addressing these issues. Specifically engineered for applications with drop heights between two metres and ten metres, this system is designed to absorb heavy aggregate impacts safely, preventing belt damage and extending the belt’s life.
The Tru-Trac EXHD Dynamic Impact Idler Bed combines dynamically adjusting impact idlers with robust shock-absorbing springs to provide superior impact control.
The impact idlers in the Tru-Trac EXHD system oscillate to adjust dynamically to the load, significantly reducing the force transmitted to the belt. This movement allows the system to absorb and dissipate impact energy more effectively than static systems. The heavy duty springs enhance this absorption, capable of handling loads up to 11.4 tonnes, working in tandem with the idlers to manage high impact conditions effectively. This advanced design ensures minimal stress on the belt, preventing damage and enhancing durability.
Blumberg says that Tru-Trac offers a range of impact control solutions tailored to specific application requirements ensuring that conveyor systems are protected from various types of impact forces. This includes standard impact beds, impact rollers and slider frames; all of which are engineered for easy installation
Tru-Trac’s EXHD Dynamic Impact Idler Bed provides a durable solution to protect belts and improve system reliability in demanding conditions.
and minimal maintenance.
Tru-Trac’s capabilities also extend to addressing dust and spillage around the impact or loading zone. “Proper dust and spillage control are essential for maintaining a clean and efficient conveyor environment and our solutions help to minimize material loss and prevent the accumulation of debris which can lead to additional wear and operational inefficiencies,” he says.
A recent case study from a copper mine in the DRC highlights the effectiveness of the Tru-Trac EXHD Dynamic Impact Idler Bed. The mine faced extreme challenges with its conveyor system, where high impact loads in the loading zone frequently caused belt damage, leading to significant
Tru-Trac’s EXHD Dynamic Impact Idler Bed offers a robust solution designed to protect belts.
downtime and maintenance costs. The existing impact system, which used traditional rollers, proved inadequate for handling the high drop heights and abrasive materials.
“Our local team conducted a comprehensive site assessment, collecting the necessary data and analysing various factors such as material properties, drop heights, existing system configurations and operational challenges,” Blumberg says. “This detailed evaluation included observing the wear patterns on the existing conveyor belt, identifying the sources and magnitude of impact forces and assessing the overall condition of the loading zones.”
“By gathering the necessary information
first hand and gaining a thorough understanding of the specific conditions and requirements, our engineering team could offer a solution that would effectively address the unique challenges faced by the site and this saw the installation of our TruTrac EXHD Dynamic Impact Idler Bed,” he says.
In this application, the system’s oscillating idlers and heavy duty springs work in tandem to absorb and disperse the severe impacts. The oscillating idlers dynamically adjust to the load, allowing them to move with the material as it falls onto the belt. This dynamic adjustment significantly reduces the direct force transmitted to the belt, preventing sudden shocks that can cause damage. The heavy duty springs complement this action by providing robust shock absorption, further minimizing stress on the belt.
“Together, these components ensure that the belt remains aligned, preventing issues such as misalignment, tearing and edge wear. By maintaining proper alignment and reducing impact related damage the system increases the belt’s longevity and reliability and has ultimately led to reduced maintenance costs and increased uptime at this customer,” Blumberg says.
It is apparent that the broader impact of poorly designed loading zones cannot be overestimated. Inadequate impact protection can lead to increased spillage, belt misalignment and structural damage to the conveyor system. Misalignment causes the belt to drift leading to additional wear on the edges and other components which, in turn, increases maintenance require-
The impact idlers in the Tru-Trac EXHD system oscillate to adjust dynamically to the load, significantly reducing the force transmitted to the belt.
The Tru-Trac EXHD Dynamic Impact Idler Bed combines dynamically adjusting impact idlers with robust shock-absorbing springs to provide superior impact control.
ments and potential operational downtime. Chutes that are not properly aligned with the conveyor can misdirect materials, creating irregular impact points and causing excessive localized stress on the belt. This can result in belt failure and significant operational disruptions.
“Tru-Trac’s EXHD Dynamic Impact Idler
Bed represents a significant advancement in conveyor belt protection, effectively addressing the complex challenges of impact control in loading zones and we believe that investing in high quality impact beds and ensuring proper chute design is crucial for maintaining efficient and reliable conveyor operations,” Blumberg concludes.
Tru-Trac’s EXHD Dynamic Impact Idler Bed represents a significant advancement in conveyor belt protection.
MODERNIZATION AND OPTIMIZATION OF DRY SLAG CONVEYING SYSTEM IN SWISS WASTE INCINERATION PLANT
CUSTOMIZED CONVEYING SOLUTIONS FOR DRY FINE SLAG FROM LOIBL
The dry fine bottom ash and slag is conveyed by various conveyor systems from Loibl, which are specially tailored to the customer’s requirements. They convey the dry residues efficiently and reliably outside the WtE (waste to energy) plant into an existing slag processing hall, where the dry fine ash and slag is sorted by five screens according to grain size for further processing.
WASTE INCINERATION PLANT EQUIPPED WITH MODERNIZED CONVEYOR SYSTEM
The fine slag is transferred to two successive troughed belt conveyors by means of an on-site vibrating conveyor and conveyed over a length of 25 metres and 85 metres. The troughed belt conveyors are completely encapsulated to ensure emission-free conveying. An intermittently operating cleaning scraper in each capsule transports the resulting dust along the entire route to the discharge point, which significantly reduces wear on the equipment.
To avoid emissions, a constant negative pressure is generated in the extracted capsules. The trough chain conveyors have side opening flaps that can be opened and removed for maintenance. They are equipped with sturdy fork link chains to ensure long-lasting operation and replace the more vulnerable round chain system.
In addition to the conveyor system,
Loibl is also supplying two support towers and two belt bridges with access on both sides and the necessary platforms for maintenance work. A stair tower in
combination with another support tower and platforms provides additional accessibility and support for the conveyors.
The new conveyor system is capable of conveying up to 65 tonnes per hour and
provides an efficient and safe working environment for fine slag transportation.
SCOPE OF SUPPLY AND SERVICES
consulting and planning; v basic and detail engineering; v production in Straubing, Bavaria v LASHBELTCON® — trough belt v conveyor. Belt conveyors from Loibl impress with their modular and robust design. They convey bulk materials of all kinds over long distances, even through rough terrain. Thanks to optimized curve radii, variable incline angles, and large axis distances, different throughputs and high conveying capacities can be realized. capacities can be achieved. The material is conveyed gently and with low wear.
LASHCHAINCON® — trough chain v conveyors. Loibl chain conveyors are an economical and reliable solution for the closed transportation of abrasive bulk materials. They are suitable for dust-free transportation and are used for distributing, discharging, dosing and cooling fine to coarse-grained bulk materials. They are customized, sturdy and durable. Trough chain conveyors offer a wide range of applications and design variants. They can be dust-tight, gas-tight, pressure-shock-proof and designed in accordance with ATEX directives. The LASHCHAINCON® is designed as a single strand or multiple strand conveyor with axis distances of up to 250m and a trough width of up to 3m. Loibl’s trough chain conveyors are also used as trickle scraper conveyors below other continuous conveyors.
TSUBAKIMOTO BULK SYSTEMS CORP. is a key division of the TSUBAKI Group. It is a global expert in the design and provision of advanced bulk material handling solutions. With a rich heritage rooted in mechanical engineering and automation, the TSUBAKI Group, established in 1917, is a recognized pioneer in creating efficient, reliable, and technologically advanced systems.
TSUBAKIMOTO BULK SYSTEMS CORP. specializes in the design, manufacture, and supply of bulk material transport systems, such as conveyors, elevators, and automated solutions. These systems are integral to industries that rely on efficient bulk material handling including cement, biomass, mining, steel, agriculture, fertilizer, chemical, and recycling.
TSUBAKIMOTO BULK SYSTEMS CORP. is committed to sustainability and technological innovation and offers solutions that enhance performance, energy efficiency, and operational reliability.
TSUBAKIMOTO BULK SYSTEMS CORP. consistently introduces cutting-edge products and services to maintain its respected position in the bulk material handling sector. The company’s innovation-
driven approach ensures that its solutions meet the evolving demands of industries worldwide.
High-efficiency conveyor systems: v designed to handle the most challenging and heavy-duty operations, TSUBAKI has introduced advanced conveyor systems that significantly improve operational efficiency. These systems are tailored for industries like mining, where materials such as ores, coal, and minerals need to be transported over long distances in harsh conditions.
Energy-efficient systems: in line with v global efforts to reduce environmental
impact, TSUBAKI has developed energy-saving conveyors that use lowenergy motors and design optimization aims to reduce wasteful power consumption. These solutions not only reduce the carbon footprint of operations but also lower the operational costs of industries that require the movement of bulk materials over long distances.
Sustainable recycling solutions: v TSUBAKI is committed to sustainability in all its facets. This is evident in its new line of conveyor systems designed specifically to support the recycling industry.
Predictive maintenance solutions: v TSUBAKI’s predictive maintenance solutions help clients identify potential system issues before they arise, preventing unexpected downtimes, costly repairs, and unnecessary disruptions to business operations.
TSUBAKI’S OPERATIONS AND ABILITIES
Product development & custom- v ization: TSUBAKI works closely with R&D teams, clients, and engineers to design and tailor material handling systems that meet the unique requirements of each client. This involves detailed consultations to understand client needs and engineering solutions that ensure optimal performance.
Project management: from the initial v planning phase to the final installation and testing of systems on-site, the company will oversee the entire project lifecycle. Managing budgets, timelines, and resources, and coordinating cross-functional teams are key to ensuring that all projects are
completed efficiently and to the highest standards.
Client support & training: after v systems are installed, TSUBAKI ensures that they continue to operate as they should. This includes providing
ongoing support, troubleshooting, and offering training sessions for client staff.
Market research & competitive v analysis: to maintain TSUBAKI’s pre-eminent position in the market, it carries out thorough market research and competitor analysis, identifying emerging trends and technologies. This will help the company adapt to industry shifts and continue offering innovative, competitive solutions.
TSUBAKI serves a wide variety of industries, providing bulk material handling systems that are essential for the smooth functioning of global industries. Major clients include:
Cement industry: world major v cement manufacturers use TSUBAKI’s advanced conveyor systems for the transport of raw materials like limestone, clay, gypsum, and clinker as well as for finished cement products. These high-capacity systems are built to withstand the demanding nature of cement production.
Biomass energy: TSUBAKI solutions v are instrumental in the biomass industry, efficiently handling materials such as wood chips, agricultural waste, and other organic materials used for energy production. These systems facilitate the seamless transport of biomass, a renewable resource that plays a key role.
Mining and steel: TSUBAKI supports v global mining giants, providing robust conveyors that transport heavy materials like coal, and slag in challenging mining environments. Steel
manufacturers also rely on TSUBAKI for the safe, efficient transport of raw materials and steel products.
Agriculture: TSUBAKI offers v specialized material handling systems to the agriculture sector, facilitating the efficient movement of crops, fertilizers, and animal feed through TSUBAKI boasts an 80% share of the conveyor systems for grain storage silos in Japan.
Fertilizer production: fertilizer v manufacturers depend on TSUBAKI systems to handle raw ingredients like phosphate, potash, and nitrogen, ensuring these materials are transported efficiently and safely throughout production.
Chemical manufacturing: chemical v companies rely on TSUBAKI customdesigned conveyors to transport a wide variety of chemicals, from powders and liquids to more complex materials, all while ensuring compliance with stringent safety and regulatory standards.
Recycling: TSUBAKI provides v recycling facilities with advanced conveyors, and it has experience transporting various types of waste and incineration ash, so it can propose the optimal conveyor system. These systems increase efficiency and support sustainability efforts within the recycling industry.
To maintain its strong market position, and to stay competitive in an ever-evolving marketplace, TSUBAKI is dedicated to continuous innovation and strategic growth.
Key initiatives include:
Investment in R&D: TSUBAKI’s v ongoing investment in research and development ensures that it remains at the cutting edge of bulk material handling technology. R&D teams focus on developing systems.
Sustainability initiatives: TSUBAKI v has made sustainability a central focus of its operations. This includes using sustainable materials in product manufacturing and reducing the energy consumption of its systems. The company also focuses on improving the energy efficiency of the entire supply chain.
Expanding global reach: to cater to v the growing demand for efficient bulk material handling systems in emerging markets, TSUBAKI is expanding its presence in regions like Southeast
Asia, Africa, and the Middle East This global reach allows the company to adapt its solutions to local market needs while maintaining high levels of service and support.
Customer-centric approach: TSUBAKI v places a strong emphasis on understanding customer needs, gathering regular feedback, and improving its solutions based on this input. This ensures that the company maintains long-term relationships and secures customer loyalty in an increasingly competitive marketplace. Collaborations and partnerships: v through strategic partnerships with other technology providers, TSUBAKI has developed integrated, innovative solutions that combine the best of both companies’ expertise. These partnerships allow for the creation of more comprehensive systems that address a wider range of client needs.
TSUBAKIMOTO BULK SYSTEMS CORP. operates as a division of the Tsubaki Group, a company that has been at the forefront of mechanical engineering for over a century. Headquartered in Osaka Japan, the company has expanded its operations across key markets in North America, Europe, the Middle East, Africa, and Asia. TSUBAKI’s strong position in bulk material handling is driven by a commitment to innovation, precision engineering, and a focus on providing high-performance, reliable solutions.
CORE COMPETENCIES: custom bulk material handling v systems; energy-efficient technologies; v maintenance services and system v upgrades; and sustainable bulk material transport v solutions.
TSUBAKI has earned a reputation for its exceptional quality control and manufacturing techniques, becoming a trusted partner for industries worldwide.
CORNERSTONES OF TSUBAKIMOTO BULK SYSTEMS CORP.
TSUBAKIMOTO BULK SYSTEMS CORP. places a strong emphasis on corporate social responsibility and community engagement:
Environmental responsibility: the v company’s eco-friendly manufacturing practices and commitment to reducing its environmental footprint reflect its broader focus on sustainability.
Employee development: the v company provides extensive training to its employees, ensuring they remain experts in the latest trends, machinery, sustainability practices, and digital technologies.
Charity and community involvement: v TSUBAKI is dedicated to supporting local communities, with charity programs, environmental initiatives, and employee volunteer efforts aimed at making a positive impact where it operates.
Conveyor belt systems are a critical part of many industrial operations, from mining and manufacturing to logistics and warehousing. Kinder has spent decades helping businesses optimize their conveyor belt systems for better performance, efficiency, and reliability.
Here, Kinder explores the critical role pulleys play in conveyor belt systems and provides practical tips on how to get the most out of them.
DRIVE PULLEYS: THE POWER BEHIND YOUR CONVEYOR BELT
Drive pulleys are the driving force behind conveyor belt systems, transmitting power from the motor to the belt. To ensure smooth operation, it’s essential to choose the right drive pulley for the application. It is vital to consider factors like belt speed, load, and wrap angle to select a pulley that meets all needs. A well-designed drive pulley will help prevent belt slippage, reduce wear and tear on the belt and motor, and ensure reliable operation. Additionally, the pulley’s diameter, material, must be considered, as well as lagging to ensure optimal performance.
TAIL PULLEYS: KEEPING THE BELT ON TRACK
Tail pulleys keep conveyor belts on track,
maintaining tension and preventing sagging. Regular inspections and maintenance are crucial to prevent premature wear and tear. Users should check for signs of wear, adjust the pulley’s position as needed, and replace worn-out components to ensure optimal performance.
It’s also essential to ensure the tail pulley is properly aligned and securely fastened to prevent belt tracking issues. By maintaining tail pulleys, users can prevent costly downtime and extend the lifespan of their conveyor belts.
Take-up pulleys help maintain tension in conveyor belts, compensating for stretch or sagging. To get the most out of take-up pulleys, they should be adjusted regularly to changing conditions. It is also important to monitor belt tension and adjust the pulley as needed to prevent over-tensioning or under-tensioning. Proper take-up pulley adjustment will help prevent belt wear, reduce energy consumption, and ensure smooth operation.
SNUB PULLEYS: IMPROVING TRACTION AND REDUCING SLIPPAGE
Snub pulleys increase the wrap angle of a conveyor belt around the drive pulley,
improving traction and reducing slippage. To maximize the benefits of snub pulleys, they should be positioned close to the drive pulley.
Proper alignment should be ensured, and belt performance monitored. Snub pulleys are particularly useful in applications where the conveyor belt is subject to heavy loads or harsh environmental conditions. By installing snub pulleys, users can improve belt traction, reduce wear and tear, and ensure reliable operation.
BEND PULLEYS: NAVIGATING CURVED CONVEYOR BELT SYSTEMS
Bend pulleys help a conveyor belt navigate curved or bent sections. To ensure smooth operation, conveyor belt systems should be designed with the bend pulley in mind. Factors like belt speed, load, and wrap angle should be considered, to select a pulley that meets your needs.
SELF- CLEANING PULLEYS: IDEAL FOR DIFFICULT MATERIAL CARRYBACK APPLICATIONS
These are specialized pulleys made for difficult applications where material buildup occurs on the pulley face, causing mistracking and belt damage. Fugitive material is ejected to either side of the pulley via the centre tapered cone.
Kinder has a comprehensive range of self-cleaning pulleys. The K-Conveyor Spiral Pulleys are designed to be used for dry and free-flowing materials. The rotation of the pulley engages the selfcleaning action therefore releasing foreign material through and on to the inner tapered cone then to the outside of the conveyor.
K-Conveyor Wing Pulleys can be used for large lump, sharp and sticky materials and are designed to be used in adverse, very abrasive and dirty applications, especially where there is material build-up on a solid conveyor pulley shell. K-Conveyor HD Wing Pulleys are designed for applications where the standard wing design may be inadequate for the duty.
Pulleys play a vital role in conveyor belt systems, impacting performance, efficiency, and reliability. By understanding the different types of pulleys and their functions, users can make informed decisions to improve their conveyor belt systems.
Kinder is committed to helping businesses achieve their goals through expert advice and innovative solutions.
Family-owned and -operated Belt Tech Industrial was established in 1991. It has three stocking locations, in Indiana, Illinois, and Tennessee. The company’s core values are: honesty and integrity, respect, pride, and drive. In 2024, Belt Tech was rated by The Indiana Chamber as one of the “Best Places To Work In Indiana”
The following question/answer session gives an overview of Belt Tech’s role in today’s bulk handling industry.
Question: In one sentence, how would you describe Belt Tech’s role in the bulk material handling industry?
Answer: Belt Tech Industrial plays a vital role in the bulk material handling industry, providing the equipment, parts, and services that keep operations running efficiently. From aggregates and coal to grain, wood chips, asphalt, and recycling, Belt Tech’s solutions ensure reliable material flow and minimal downtime.
Q: What makes Belt Tech stand out from competitors?
A: Belt Tech stands out because of its responsiveness, safetyfirst approach, and commitment to quality service. High stocking levels, after-hours support, and adaptable solutions, have helped it earn its customers trust.
Q: What are some notable projects that Belt Tech has recently completed or is currently working on?
A: Recently, Belt Tech has completed several major projects, including scraper installations at multiple Top-3 aggregate producer locations, primary and finished-product belt replacements with vulcanizing, and conveyor removal, rebuild,
A lack of maintenance can lead to catastrophic damage.
and relocation projects for various aggregate producers. Notably, it installed 70,000 feet of 48-inch belt for a coal mine overland conveyor project, demonstrating its expertise in large-scale material handling solutions.
Q: Has Belt Tech entered any new markets or expanded its services recently?
A: Belt Tech has expanded into new markets, including scrap yards, recycling operations, concrete batch plants, ports and terminals. In addition to its core conveyor services, it has also broadened its offerings to include pumps and conveyor fabrication, further enhancing its ability to meet the diverse needs of bulk material handling industries.
Q: Can you share an example of a major problem that Belt Tech has solved for a customer?
A: A customer dealing with severe dust, spillage, and belt slippage on an HSI discharge conveyor needed a reliable solution. Belt Tech identified the root causes and implemented a targeted fix — installing a snub pulley to eliminate slippage and outfitting the system with proper impact beds, clamp bars, and skirting. As a result, the customer saw a significant reduction in material loss, improved belt performance, and a cleaner, more efficient operation.
Q: What advancements or improvements in conveyor technology has Belt Tech introduced recently?
A: Recent advancements in conveyor technology include the introduction of pneumatic riveters, which have significantly reduced turnaround time for pre-made belts from Belt Tech’s shop. Additionally, through ASGCO, Belt Tech now offers a self-driven brush cleaner that enhances belt cleaning efficiency while minimizing maintenance requirements.
Q: How is Belt Tech using automation, monitoring systems, or other smart technologies to improve bulk material handling?
A: Belt Tech enhances bulk material handling through automation and smart monitoring systems, offering monthly scraper audits and annual belt audits. Customers receive detailed PDFs or spreadsheet reports, allowing them to track performance, identify issues early, and optimize their conveyor systems efficiently.
Additionally, Belt Tech is an authorized dealer for perma, an expert in automatic lubrication systems. One recent innovation
is perma STAR VARIO LONG RANGE. It operates fully automatically, independent of temperature and pressure with a very precise discharge. Thanks to LoRa® wireless technology, up to 2,000 lubrication systems in a facility can be conveniently managed via perma CONNECT over a distance of up to 1.2 miles
Q: What are some of the most requested
features or upgrades from customers?
A: Some of the most requested products and features that customers request include straight-warp belting, primary and secondary belt cleaners, impact beds, HD wing pulleys, urethane skirting, and used belt. Belt Tech strives to accommodate its customers’ needs while also educating them about the hidden costs associated with purchasing used belt.
Q: What are the biggest challenges that customers face when it comes to conveyor systems?
A: Customers face a variety of challenges, including poor maintenance, which leads to unplanned downtime, as well as an unskilled and inexperienced workforce. Unscheduled downtime related to belt failure is another common issue. Part of Belt Tech’s role is providing training on proper maintenance, and it has offered several live training courses free of charge.
Belt Tech views this as a worthwhile investment, as it fosters goodwill with customers and ultimately benefits everyone involved.
Q: What trends do you see shaping the future of bulk conveying?
A: Some of the key trends shaping the future of the material handling industry include vendor-provided maintenance services, increased automation and remote monitoring, online shopping for components, and the use of electronic belt monitoring.
Q: What is the one thing that a potential customer should know about Belt Tech, and why should they choose it over other suppliers?
A: Belt Tech is fast, detail-oriented, and experienced, with a strong focus on providing lasting solutions, not just quick fixes. It offers premier service and competitive parts pricing.
Pneumatic conveying system.
With the range and reliability to handle applications from cement plants to processing and port systems, FLSmidth Cement’s pneumatic conveyors improve its customers’ bulk material handling. Its strong track record and understanding of challenges and opportunities with pneumatic conveying systems enable it to deliver enhanced safety, productivity and efficiency.
Achieving optimum flowability and fluidization is imperative. But handling dry bulk materials can be challenging. They can be abrasive. Prone to attrition. If a system isn’t fully enclosed, dust can escape. Unsuitable conveying system design can cause blockages, under-performance and build-up. Even worse, there is a risk of unplanned changes in bulk characteristics. All of which cost time and money to put right.
Traditional mechanical conveying solutions have a lot of moving parts, which require a lot of maintenance, which necessitates downtime.
Once again this wastes a lot of time and money. This can also pose a safety risk to personnel.
Pneumatic conveying offers a safe and reliable solution with the added benefit of flexibility and low operational costs. These space-saving systems will take the material where it is needed, regardless of the terrain
or what other equipment the system must work around.
PNEUMATIC CONVEYING SOLUTIONS FOR MULTIPLE APPLICATIONS
FLSmidth is a major supplier of pneumatic conveying equipment and serves industries such as cement, mining, power generation, lime, and pulp and paper. Its products and systems are proven to provide clean, safe, economical methods to meet virtually every pneumatic conveying and storage application. As a customer-driven organization, FLSmidth Cement continually seeks broader uses for its products, processes and technology to meet the ever-increasing demands of emerging and diverse applications.
From low energy, dense phase conveying systems, to high-efficiency blending systems, the development of new products evolves to meet the specialized needs of global customers.
FLSmidth Cement’s research team actively seeks out problems so that it can solve them before they occur. Varying process conditions are simulated in the laboratory so that the effect on the conveying system can be confirmed prior to actual installation.
IN PNEUMATIC CONVEYING
Conveying systems should move materials where they are needed, at the speed and density the operator requires. FLSmidth Cement’s systems are designed on that basis. The customer explains what they
need, and FLSmidth Cement finds the right solution, not just the closest fit from a handful of ‘not quite right’ solutions. Its range of pneumatic transport systems includes options for dense, medium and dilute phase conveying; pressure vessel, screw pump or Airslide® air gravity conveyor systems; high pressure or low pressure, but always low maintenance, clean and efficient.
PRESSURE VESSEL SYSTEMS
For customers that want to transport bulk material safely and with low maintenance, FLSmidth’s Pressure Vessel Systems are the right choice. This economic pneumatic conveying system is also suitable for high capacities and strongly abrasive bulk materials. It enables throughputs up to 1tph (tonnes per hour) to 300tph and conveying distances up to 1,600m (one mile) without intermediate stations.
PNEUMATIC CONVEYING SYSTEMS VERSATILE SOLUTIONS FROM A SINGLE SOURCE
Conventional conveying systems. v Dense phase conveying systems. v Pressure vessel systems. v Fuller-Kinyon® pumps. v Ful-Vane™ compressors. v Airlift™ systems. v Airslide® air gravity conveyors. v Silo systems of all sizes and models. v Unloading stations for ships, trucks v and rail.
Loading stations for trucks, rail and v ship.
THE ORIGINAL FULLER® AIRSLIDE® GRAVITY
CONVEYING SYSTEM FOR EFFICIENCY
FLSmidth’s Airslide® air gravity conveying system utilizes gravity to do most of the work. Material is fluidized through a porous media with low-pressure air and the Airslide is sloped to match the fluidized angle of repose of the powdered material. At the correct slope, fluidized materials flow like a liquid.
High capacities, +1,500m3/hr (53,000 v cf/hr).
Multiple inlet and discharge options. v Fabric available for high temperature v applications up to 454°C (850°F).
Airslide gravity conveyors have no moving parts, so there is low noise and low maintenance costs — just clean, gentle conveying.
DENSE PHASE SYSTEM FOR MAXIMUM EFFICIENCY AND COST EFFECTIVENESS
There are three alternatives for dense phase conveying, designed to provide options for every application.
MODU-DENSE™ conveying system. v Maxi-Dense™ dense phase system. v Pressure tank system. v
MIXED PHASE FULLER-KINYON® PUMP TRANSFER SYSTEMS
Heavy-duty, screw-type Fuller-Kinyon pneumatic pumps are commonly used to convey dry, free-flowing materials from grinding mills, transfer materials from silo to silo, transfer dust from collectors, and load and unload railcars, ships and barges. Continuous operating systems, reliable for 24/7 duty.
Lower velocities and higher pressure v than dilute phase.
Most economical and reliable long- v
distance, high-capacity technology.
Operational simplicity — only one v moving part.
Maintenance-friendly access. v Pneu-Flap™ torque arm controller v reduces maintenance costs, lowers power consumption and increases capacity.
FK Auto-Lube lubrication system v delivers precise amount of lubrication for each FK pump while monitoring bearing temperatures.
The materials are conveyed literally v anywhere a pipeline can be run and to any number of delivery points.
Distances of 1,585 metres (5,200 feet) are not uncommon.
FLSmidth offers a full range of single-stage and two-stage compressors; from critical parts to complete self-contained packages.
Packages may be custom built to project specifications or FLSmidth standards. Auxiliary components are available upon request. The Ful-Vane compressor is the perfect marriage with Fuller-Kinyon® pump packages for ultimate reliability.
Large inlet area provides efficient v capture of large air flows.
Only three moving parts for minimal v mechanical losses.
Constant blade-to-cylinder contact v results in sustained compression efficiency.
Shaft and bearing design minimizes v drive losses; suited for operation with VFD.
Ful-Lube™ automatic compressor v lubrication system available separately. Closed loop cooling available. v
FLSmidth Cement’s Ful-Vane compressor is
designed to allow the cylinder to be rebored and rotor to be reslotted several times, giving customer the highest return on investment within the industry.
Ful-Pak™ packaged air compressors are the ideal solution for the demanding conditions of pneumatic conveying applications. Compact and totally selfcontained in a low-noise enclosure, it is the complete air power source for reliable, efficient operations.
THE PERFECT PARTNERS FOR YOUR PNEUMATIC CONVEYING APPLICATION
The most efficient pneumatic conveying solution on the market. Efficiency. Cleanliness. Reliability. That’s what customers need in a materials-handling solution. And that’s what they get when they pair the FK N Pump with the FV Compressor — a robust, reliable solution proven by a century of experience in the field and continually improved to give optimum value.
FLSmidth Cement’s Fuller-Kinyon screw pump works efficiently to push material from its gravity-fed hopper through the barrel into the discharge body, where the Ful-Vane™ Compressor provides the required compressed air to convey the material through the transport line. Both machines are durable and easy to maintain, with the capability to be installed in any plant environment.
THE ULTIMATE PNEUMATIC CONVEYING SOLUTION: PAIRING THE FK N PUMP WITH THE FV COMPRESSOR
The FLSmidth Fuller-Kinyon screw pump works efficiently to push material from its gravity-fed hopper through the barrel into the discharge body, where the FLSmidth
Pressure tank system.
Ful-Vane™ Compressor provides the required compressed air to convey the material through the transport line. Both machines are durable and easy to maintain, with the capability to be installed in any plant environment.
Originally designed in 1918 as a way to safely transport pulverized fuels, the FullerKinyon® screw pump has proven itself to be a must-have component in materials handling systems worldwide.
The latest generation, the FK N Pump, is based on the same design principles as the M Pump, but includes upgrades that enable higher convey line pressure with greater energy efficiency, as well as the ability to serve ship and barge unloading applications.
The screw pump hopper is gravity-fed. Materials are pushed through the barrel by the screw, which compacts the material as it advances.
The material density is further increased in the space between the terminal flight of the screw and the face of the non-return valve, forming a seal against the transport line pressure, which prevents blowback. When the material enters the discharge body it is fluidized by compressed air and conveyed into the transport line.
STANDARD FEATURES
Cast iron and steel construction, with v a cast iron base.
Ball bearings support a pump screw at v both ends for smooth, balanced operation.
Critical parts that come into contact v with material to be conveyed are made of hardened, wear-resistant material and special hard surfacing.
Screw is coupled to the driving motor v but can be v-belt driven. Easy, low-cost maintenance thanks to v the 3-piece screw.
Diameters from 150mm – 350mm v with capacities up to 600tph, depending on bulk density. Conveying air pressure range up to v 35psig (~2.4 Bar).
Built to withstand material v temperatures up to 400 °F (~200 °C) as standard.
FK N PUMP UPGRADES
To further improve efficiency, the FK N pump comprises four main improvements from the previous model: Improved throughput. v Higher volumetric efficiency and v
higher convey line pressures. Power savings. v Dual discharge housing as standard. v
Common applications include conveying dry, free-flowing pulverized materials from grinding mills, between silos, transport from dust collectors, and for loading and unloading railcars, ships and barges.
For other applications, materials can be conveyed literally anywhere a pipe can be run. Long conveying distances are not uncommon, including in excess of 5,000ft (~1,525m).
CUTTING THE COST OF COMPRESSED AIR WITH THE UPGRADED FV COMPRESSOR
Compressed air is one of the biggest energy consumers in any heavy industry process.
However, pneumatic conveying is an excellent way to move materials. For decades, FLSmidth Cement has dedicated its expertise to creating a solution that lowers the cost of compressed air. And with the latest upgrade, it offers the world’s most cost-effective compressor.
BENEFITS
Long life. v Low maintenance. v
Suitable for harsh, dirty plant v environments.
Energy efficient. v Low total cost of ownership. v
STRAIGHTFORWARD DESIGN MAXIMIZES EFFICIENCY
The design of the FV compressor has long focused on straightforward, logical engineering. A large inlet area enables the efficient capture of large air flows. By keeping moving parts to an absolute minimum — just three — FLSmidth Cement has minimized mechanical losses. And the constant blade-to-cylinder contact results in constant compression efficiency. The compressor is also suited for operation with a variable frequency drive, for increased energy efficiency. The upshot? More compressed air with less energy.
Cast or ductile iron cylinder allows for v up to five re-bores.
Solid one-piece rotor and shaft can be v re-slotted several times for different blade thicknesses.
Shaft and bearing design minimizes v drive losses.
Integral cooling water jacket v Inlet/outlet configuration eliminates v internal compression losses.
Mechanical seal for gas applications. v
UPGRADES THAT REDUCE CAPITAL COSTS AND OFFER INCREASED VOLUMES
Recent upgrades make the FV compressor even more cost-effective.
The compressor cylinder and heads v have been redesigned to simplify the castings, which, for most designs, reduces build costs — a saving that ensures the customer gets the lowest possible total cost of ownership. FLSmidth Cement has also standardized the compressor design across all sizes so that all have round profiles, but kept the mounting position the same so that customers can more easily upgrade from an older model.
The cooling water jackets have also v been redesigned, reducing weight and minimizing costs.
On the larger models, FLSmidth v Cement has standardized to a single discharge flange. These changes enable the compressor to run at a higher RPM, giving customers the option of more volume in a smaller size compressor.
PERFECT PARTNER FOR THE FK N
The FV Compressor is the perfect marriage with the FK N Pump for ultimate reliability. Choose from a full range of single-stage and two-stage compressors, from critical parts to complete selfcontained packages. Packages may be custom built to project specifications or FLSmidth standards. Auxiliary components are available upon request.
WEG MOTION DRIVES: MOTORS AND DRIVES TRANSFORM CONSTRUCTION MACHINERY
SBM RELIES ON WEG MOTION DRIVES IN ITS MOBILE CONCRETE MIXING PLANTS
SBM Mineral Processing (SBM), a member of the international MFL Group, which is headquartered in Oberweis, Austria, facilitates economical concrete production and processing. The company creates mobile concrete mixing plants and consistently relies on drive systems from WEG, the motors and drives specialist, to drive a variety of conveyor belts in its mobile mixing plants. This includes the supermobile EUROMIX 400C plant.
SBM specializes in the development and production of concrete mixing plants, and in processing and conveying systems for the natural stone and recycling industries.
The Austrian company is a full-service supplier in the ready-mixed and prefab concrete sector and has both mobile and stationary concrete mixing plants in its product line.
The supermobile EUROMIX 400C unit is one of the company’s special solutions and boasts its own electrical generator for fully autonomous operation. It is compact, powerful and has approval to be transported via the public highway.
The Dutch recycling company Van Gansewinkel uses the EUROMIX 400C to process materials such as excavated soil, bottom ash, sludge and sieved sand into concrete suitable for long-term storage.
The plant operates in continuous
operation with an effective production capacity of more than 400 tonnes concrete per hour. For the 400C model as for other EUROMIX plants, SBM relies on geared motors from WEG for the conveyor belt drives.
Several conveyor belts with reliable drive systems are necessary for smooth operation of the concrete mixing plant. The aggregate is weighed and dispensed according to the desired concrete grade and fed to the steep-angle conveyor belt, which in turn transports the material to the double-shaft mixer.
Cement, water and the necessary additives are fed directly into the mixer. The resulting concrete can be taken away by lorry or by ready-mix concrete trucks. Extreme operating and environmental conditions, high availability and optimal plant use impose high demands on the drive systems. The geared motors must be protected against humidity as well as extreme dust loading.
Along with robustness, reliability is especially crucial for job-site operation. P articularly for motorway or tunnel construction, a continuous supply of concrete is essential. The compact design and high mobility of the EUROMIX 400C also requires low-profile gear units with flexible mounting options.
The drive technology from WEG used in
the SBM mixing plants includes various types of gear units from the K Series with torque ratings from 2,700 to 20,000 Newton metres (Nm). The EUROMIX 400C has a pair of helical bevel geared motors, type KUA 85A 70 134M4, rated at 7.5 kilowatts (kW) for the two dispensing belts and an angle parallel shaft geared motor, type CSA 80A 70 161M4, rated at 11kW for the steep-angle conveyor belt.
The compact, structurally optimized housing of the helical bevel geared motors has efficiency class IE2, speed 22 revolutions per minute (rpm) at 50 Hertz (Hz), torque 3,274Nm, controlled by frequency inverters and housing in UNIBLOCK design provide flexible mounting options.
What’s more, these motors come with the option of humidity protection, condensation bores, temperature control using positive temperature coefficient (PTC) technology, forced ventilation and protective covers.
The K series gear units offer rapid, adaptable solutions to tailor to specific customer needs. Collaborating with SBM, WEG customized drives to suit environmental conditions and individual requirements for the EUROMIX 400C.
Specifically designed for this application, the helical bevel and angle parallel shaft geared motors feature special functions like humidity protection, condensation bores, PTC temperature control, forced ventilation and protective covers.
In addition, the angle parallel shaft
geared motor includes a modular backstop for added protection, preventing reverse motion of the steep-angle conveyor belt during power outages.
VERSATILE, COMPACT AND RELIABLE
The reliability and high quality of the geared motors from WEG reinforce the confidence of SBM’s customers in the availability and productivity of the SBM concrete mixing plants.
Low maintenance, robustness and long life are especially crucial attributes of drives for mobile use in job-site conveyor systems. The combination of high operational reliability and outstanding versatility makes the modular drives units from Watt Drive an optimal solution for flexible, demanding applications like the EUROMIX 400C.
There’s a good reason why SBM relies on gear systems from WEG for all EUROMIX plants. The combination of high operational reliability and excellent versatility makes the modular drives units from WEG an optimal solution for flexible, demanding applications such as the EUROMIX 400C.
CURRENT EUROMIX REFERENCES
A current project employing the
combination of SBM concrete mixing plants and WEG technology is the 4.4km Götschka Tunnel on the S10 motorway in Austria, which forms the traffic corridor between Linz and Prague. Here, three mobile EUROMIX plants, types 2000, 3000 and 4000, produced a total output of 300,000 cubic metres (m3) of concrete between spring 2012 and 2015.
The plants operate around the clock regardless of season and weather, and thanks to its high-quality configuration — including K Series gear units from WEG — they fulfil the demanding Austrian specifications for tunnel construction.
Notably, WEG and SBM also partnered in the construction of the S10 motorway in Austria, where a EUROMIX 4000 with conveyor belts powered by reliable WEG motion drive technology produced concrete for the motorway substructure.
WEG MOTORS REVOLUTIONIZE STAINLESS
STEEL PRODUCTION
BRAUN USES WEG PRODUCTS TO DRIVE
AUTOMATION IN MATERIAL HANDLING
Braun Maschinenfabrik supplied a complete abrasive cut-off machine for hot cutting of radially forged bars to a stainless-steel plant in Bolzano, Italy. Braun had to integrate a fully automated material handling system
for their abrasive cut-off machine with limited transfer height, needing innovative conveyor system designs to ensure efficient cutting of forged pieces with varying lengths. That’s why WEG, the motors and drives specialist, was asked to supply 68 motors to integrate in the forging line.
Set up in 1848, Braun is a family-owned business which is currently centred on three fields: hydraulic steelwork, steel cutting and grinding machines and concrete cutting and drilling machines. The company is headquartered in Vöcklabruck, Austria and is one of the leading international manufacturers of state-of-the-art highperformance abrasive cut-off machines for cold and hot cutting, and high-pressure grinding machines for steel and non-ferrous metals.
Braun designed a special material handling system at the stainless-steel mill in Bolzano, operated by Acciaierie Valbruna S.p.a. They used a TS 12 W abrasive cut-off machine and installed Watt Drive-geared motors to drive the different units of the system.
TRICKY HANDLING TASK
The abrasive cut-off machine in Bolzano was integrated by Braun in an existing forging line. Its task was to cut off the ends
of the hot forged parts upon completion of the forging process. Previously, finished forged pieces of 2.5 to 5.5m in length were unloaded by the forge manipulator, transferred onto a roller table running parallel to the system and then ejected as single steel bars.
Longer forged pieces between five and 13m in length were grasped by a simple device and pushed out using the manipulator. One challenge for the new design of the material handling system was the limited transfer height of 0.5m for the forge manipulator, because the roller table on the abrasive cut-off machine was substantially higher, at 1.09m. The aim here was to move the forged pieces from both the unloading positions onto a single roller table line at the same height as the table at the abrasive cut-off machine.
TWO PATHS, ONE GOAL
Several new conveyor system designs were required to implement the ambitious handling process. Firstly, the 2.5 to 5m-long forged pieces were automatically moved on by a material transfer device consisting of four transport carriages from the unloading roller table, to the height-adjustable roller table located 3.5m away or placed in one of five buffer positions.
The larger forged pieces of five to 13m long were then fully automatically taken out of the forge manipulator by a material transfer unit, applying power and guide rollers and placed continuously on the height-adjustable roller table. The locking movement is provided by hydraulic cylinders with synchronized controls. The conveyor rollers are driven electromechanically.
The latter drive systems consist of two WEG K75 type helical-bevel geared motors with power ratings of 3kW. The geared motors feature protection class IP55 and provide a reduction ratio of i=51.02 with an output speed of 28 rpm and an output torque of 1,012Nm.
The height-adjustable roller table, approximately 11.5m long, removes the shorter forged pieces from the transport carriages using a lifting movement, featuring electromechanical onward movement and lifting using hydraulic cylinders — picking the longer forged pieces up directly from the drawing unit.
All the forged pieces are then moved by the height-adjustable roller table from the outlet height of 0.5 to 1.09m, the level of the roller table at the abrasive cut-off machine. The materials are carried by 17
individually electromechanically driven rollers. There, and on the cut-off machine feed and outlet roller tables as a whole, 59 identical WEG A46 type shaft-mounted geared motors with a power rating of 0.75kW each are used, two of which have incremental encoders (1,024 HTL).
With an output torque of 106Nm and a reduction ratio of i=20.86, the geared motors run at a speed of 68rpm. Due to the large amounts of heat generated during hot cutting, the drives are specially designed to operate in surrounding temperatures of up to +60°C and are also fitted with a temperature control (bimetal switch).
The lifting movement of the heightadjustable roller table is also provided very economically via an electromechanical system powered by a WEG F131 type parallel shaft geared motor with a power rating of 15kW. The drive system features a spring-loaded brake with a braking torque of 100Nm and through the reduction ratio of i=76.05 selected, it produces an output torque of 7,462 Nm.
Upon completion of the abrasive cutting procedure, the forged pieces are taken out of the machine and moved on for cooling to the chain conveyor or the chain vat. The chain conveyor drive systems, two F111 type parallel shaft geared motors with a power rating of 3kW each, are designed to operate in surrounding temperatures of up to +60°C and are fitted with a temperature control (bimetal switch).
“The compact design of the WEG geared motors enable us to deal with many complex tasks in the field of material handling”, said Stefan Purrer, head
WEG helical bevel geared motor.
construction and project engineer for steel cutting and grinding machines at Braun.
“The automation technology for the synchronization of these three interrelated material handling units, together with the interface with the existing radial forging machine, constituted a particular challenge in this project. We really appreciate WEG expert support, short delivery times and high level of supplier reliability.”
Included in the WEGmotion Drives solution is the space-saving modular watt geared motors. These components enable very fine speed adjustments, even at low speeds. This versatile package that integrates motors, drives, gears and digital innovations to enhance the productivity of steel plants delivers the perfect synergy of efficiency, reliability, and performance.
Engineered with precision and built to the highest industry standards, WEG’s allin-one packages simplify installation, reduce maintenance and optimize operations.
Founded in 1961, WEG is a global electricelectronic equipment company, operating mainly in the capital goods sector with solutions in electric machines, automation and paints for several sectors, including infrastructure, steel, pulp and paper, oil and gas, mining, among many others.
WEG stands out in innovation by constantly developing solutions to meet the major trends in energy efficiency, renewable energy and electric mobility. With manufacturing units in 15 countries and present in more than 135 countries, the company has more than 39,000 employees worldwide. WEG’s net revenue reached R$ 29.9 billion in 2022, 50.3% from external markets.
Cambelt International Corporation has been a pioneer in the design and manufacturing of high incline conveyors and equipment since the early 1960s.
Based in Salt Lake City, Utah, Cambelt specializes in high incline conveyor systems, offering a range of solutions tailored to meet the unique needs of various industries.
Cambelt International manufactures a variety of high incline conveyor systems, including:
ST (straight) conveyors: ideal for v transporting materials over long distances without turns.
L (single turn) conveyors: designed v for applications requiring a single directional change.
Z (double turn) conveyors: suitable v for complex routing with two directional changes.
CamWall & CamFlex conveyor belts: v these one-piece moulded sidewall belts are engineered for durability and efficiency, making Cambelt a heavy weight belt champions of the world.
Cambelt’s conveyor systems are versatile and can handle a wide range of commodities, including:
Mining materials: transporting ores v and minerals.
Oil and gas: handling drilling mud, frac v sand, and other drilling by-products.
Agricultural products: moving grains, v seeds, and other bulk agricultural materials.
Cement and construction: conveying v cement, sand, and aggregates.
Food processing: transporting grains, v flour, and other dry food products.
Recycling: handling paper, plastics, v metals, and other recyclable materials.
Cambelt International serves a diverse clientele, including Fortune 100 and 500 companies. Some of their major clients include:
Mining companies: handling bulk v materials in mining operations.
Oil and gas companies: providing v solutions for material handling in drilling and extraction.
Cement manufacturers: ensuring v efficient transport of cement and related materials.
Food processors: supporting the v
movement of dry bulk solids in food production.
Recycling facilities: managing the v conveyance of recyclable materials.
To stay competitive in the market, Cambelt International focuses on innovation and customer satisfaction while continuously investing in research and development to improve the conveyor systems’ efficiency, durability, and versatility. Additionally, Cambelt emphasizes American-made quality, ensuring that all products are
designed, engineered, and manufactured in the USA.
Cambelt International has recently secured several significant contracts and changes, including:
RAM Enterprise partnership: a v strategic partnership with RAM Enterprise to provide high incline conveying and material handling services solutions.
Transloader production line: v launching a new transloader
production line to meet the growing demand for efficient rail car unloading with units in stock as well as a new rental programme.
Cambelt International is at the forefront of technological advancements in conveyor systems. Recent developments include: Patented external bearing systems: v enhancing maintenance accessibility and reducing downtime.
Patented eliminator take-up v system: preventing material build-up in the tail area.
New cockpit design: improving v manoeuvrability and control with safety in mind.
Fastest belt technology: reducing v truck unload times to as low as 7–10 minutes.
Smallest footprint: minimizing space v requirements while maintaining high performance.
Cambelt International’s commitment to quality, innovation, and customer satisfaction has solidified its strong position in the high incline conveyor systems industry. With a focus on meeting the unique needs of various industries, Cambelt continues to provide reliable and efficient solutions for high incline material handling challenges. Cambelt is a highly respected expert in the high incline conveying arena.
Founded in 1985 Lorbrand has grown into a global expert in the design and manufacture of conveyor idlers and pulleys. What began as a vision shared by Alfred Granig and his three sons has transformed into an internationally recognized company, synonymous with engineering excellence and innovation. With an expansive network spanning 30 countries, Lorbrand continues to set new standards in bulk material handling, ensuring that its clients receive the best quality idlers and pulleys at the lowest total cost of ownership.
Lorbrand’s engineered-class pulleys are designed and manufactured in-house for any application within the bulk materials handling industry. Each pulley that leaves the premises, from the smallest snub pulley to Lorbrand’s largest dual-drive pulleys weighing in excess of 20 tonnes, undergoes rigorous testing and precision manufacturing to ensure structural integrity and longevity. Lorbrand offers various lagging options such as hot or cold vulcanized rubber, hot or cold vulcanized rubber backed ceramic, direct bond
ceramic and hot cast polyurethane. End disc designs such as T-bottom, Asymmetric-T and Turbine are chosen for the required service duty. Lorbrand optimizes its drum designs for weight, flexibility and strength, while selecting appropriate locking elements based on bending moment & torque capacity requirements. Additionally, it manufactures stainless steel, internal bearing, slatted and wing pulleys — a reflection of the company’s expertise in designing heavyduty solutions for high-capacity conveyor systems.
Lorbrand’s revolutionary frictionless centrifugal self- cleaning seals offer customers the lowest running friction idler on the market. Lorbrand manufactures an extensive range of idler rolls and frames such as steel rolls, fibre filled composite rolls, rubber and polyurethane disc return rolls, impact rolls, aluminium and stainless steel rolls. A full range of idler frames and overland modules are also designed, manufactured and painted in-house.
Furthermore, Lorbrand manufactures conveyor structures and ancillary equipment, including custom-designed idler
modules and impact cradles. These components are tailored to meet specific project requirements, allowing for seamless integration into both new and existing conveyor systems. With a focus on precision engineering and in-house quality control, Lorbrand continues to provide reliable and innovative conveyor solutions for industries worldwide.
Lorbrand’s conveyor systems are designed to handle a diverse range of bulk materials, making them an essential component in industries such as mining, agriculture, and shipping. The company’s high-performance conveyor solutions are widely used to transport minerals and ores, including iron ore, copper, and bauxite. These commodities require robust and efficient material handling systems to ensure smooth operations in large-scale mining and processing facilities.
In the energy sector, Lorbrand’s conveyors play a crucial role in the movement of coal, facilitating its transportation from mines to power plants
and export terminals. With the growing demand for efficiency and environmental compliance, Lorbrand’s advanced conveyor technology helps reduce spillage, dust emissions, and energy consumption, aligning
with modern sustainability initiatives.
Beyond mining, the company’s equipment is integral to industries that handle aggregates, such as crushed stone, sand, and gravel. These materials are
essential for construction and infrastructure projects, requiring durable conveyor systems that can withstand heavy loads and harsh environmental conditions. The agricultural sector also benefits from Lorbrand’s solutions, particularly in the handling of grain and fertilizers. Efficient bulk transportation of these commodities is critical for maintaining supply chain efficiency and meeting global food production demands. Lorbrand’s conveyor systems help optimize storage, processing, and distribution while minimizing product loss.
Beyond manufacturing, Lorbrand places a strong emphasis on engineering innovation and rigorous testing. Its in-house experts utilize advanced FEA and cutting-edge testing equipment to ensure optimal product performance. Every component undergoes comprehensive quality control, including roll friction testing, roll load testing as well as seal water and dust ingress testing.
Lorbrand continuously pushes the boundaries of conveyor technology through product development, market research, and client-driven innovation. Along with the continued development and testing of Lorbrand standard offerings, the company is continuously developing and prototyping new products.
The latest development is the Lorbrand sensor seal, a data capture and transmitting device installed in an idler roller’s seal. This innovation will allow customers to receive live data on their conveyor’s performance and, through machine learning, predict scheduled maintenance needs and assess the current “health” of the conveyor.
Sensor seal technology: revolution- v izing idler roll roller condition monitoring real-time temperature rpm and vibration, predictive maintenance capabilities, and wireless communication between rollers.
In-house conveyor testing facility: a v 50m test conveyor dedicated to validating new technologies and refining product designs.
Custom take-up housings: in-house v manufacture of custom CNC machined take-up housings of any kind and at a competitive price.
As industries across the globe strive for greater efficiency, safety, and sustainability, GURTEC is showing the way in developing innovative conveyor components that meet the challenges of today and tomorrow. With over 55 years of experience, GURTEC is at the forefront of the material handling industry, continually pushing boundaries to deliver solutions that improve operational performance, reduce downtime, and ensure a safer working environment. GURTEC — Backbone of Your Conveyor.
Founded in 1969, GURTEC has built its reputation as a major manufacturer of highquality conveyor components. Every component produced is a testament to the company’s dedication to precision, reliability, and innovation, proudly carrying the ‘MADE IN GERMANY’ label. By combining world-class engineering with state-of-the-art technology, GURTEC provides its clients with products that meet the highest standards of durability and efficiency.
Since its inception, GURTEC has consistently been a pioneer in the field. In the 1980s, the company revolutionized the conveyor industry by introducing plastic-
coated steel rollers and frames — an innovation that set new standards for durability and wear resistance. This forward-thinking approach to product development has been integral to the company’s continued success and leadership in the global market.
GURTEC’s comprehensive range of conveyor components includes rollers, frames, pulleys, belt cleaners, and safety devices. These products are engineered to meet the specific needs of various industries, ensuring seamless operation and minimizing maintenance costs. Whether it’s in mining, cement, ports, steel production, or recycling, GURTEC’s products are designed to improve the efficiency and reliability of material handling systems worldwide.
Ports and terminals: with GURTEC v components, high-volume operations benefit from reduced delays and optimized throughput.
Cement: designed to handle abrasive v materials like limestone and clay, GURTEC rollers enhance wear resistance, cutting down on downtime and keeping operations running
smoothly.
Steel production: GURTEC’s durable v rollers stand up to extreme temperatures and high loads, ensuring reliable material transport even in the toughest conditions.
Power plants: built for heavy-duty v applications, GURTEC’s products handle abrasives and heavy loads, reducing downtime and improving operational efficiency.
Recycling and waste management: v GURTEC components help streamline recycling processes, extend component lifespan, and improve system efficiency.
Mining and tunneling: in the v demanding world of mining, GURTEC rollers minimize friction and withstand harsh conditions, reducing maintenance costs and improving overall productivity.
At the heart of GURTEC’s success lies its commitment to continuous innovation. Over the years, the company has introduced several breakthrough technologies that have transformed the conveyor systems industry:
As industries across the globe strive for greater efficiency, safety, and sustainability, GURTEC is showing the way in developing innovative conveyor components that meet the challenges of today and tomorrow. With over 55 years of experience, GURTEC is at the forefront of the material handling industry, continually pushing boundaries to deliver solutions that improve operational performance, reduce downtime, and ensure a safer working environment. GURTEC — Backbone of Your Conveyor.
Founded in 1969, GURTEC has built its reputation as a major manufacturer of highquality conveyor components. Every component produced is a testament to the company’s dedication to precision, reliability, and innovation, proudly carrying the ‘MADE IN GERMANY’ label. By combining world-class engineering with state-of-the-art technology, GURTEC provides its clients with products that meet the highest standards of durability and efficiency.
Since its inception, GURTEC has consistently been a pioneer in the field. In the 1980s, the company revolutionized the conveyor industry by introducing plasticcoated steel rollers and frames — an innovation that set new standards for durability and wear resistance. This forward-thinking approach to product development has been integral to the company’s continued success and leadership in the global market.
GURTEC’s comprehensive range of conveyor components includes rollers, frames, pulleys, belt cleaners, and safety devices. These products are engineered to meet the specific needs of various industries, ensuring seamless operation and minimizing maintenance costs. Whether it’s in mining, cement, ports, steel production, or recycling, GURTEC’s products are designed to improve the efficiency and reliability of material handling systems worldwide.
Ports and terminals: with GURTEC v components, high-volume operations benefit from reduced delays and optimized throughput.
Cement: designed to handle abrasive v materials like limestone and clay, GURTEC rollers enhance wear resistance, cutting down on downtime and keeping operations running smoothly.
Steel production: GURTEC’s durable v rollers stand up to extreme temperatures and high loads, ensuring reliable material transport even in the toughest conditions.
Power plants: built for heavy-duty v applications, GURTEC’s products
handle abrasives and heavy loads, reducing downtime and improving operational efficiency.
Recycling and waste management: v GURTEC components help streamline recycling processes, extend component lifespan, and improve system efficiency.
Mining and tunneling: in the v demanding world of mining, GURTEC rollers minimize friction and withstand harsh conditions, reducing maintenance costs and improving overall productivity.
At the heart of GURTEC’s success lies its commitment to continuous innovation. Over the years, the company has
In 1949, Paul Hedfeld founded Paul Hedfeld KG, a company focused on the production of machines to convey grain and flour, as well as wear parts for mills and compound feed plants. Today, Paul Hedfeld GmbH is a medium-sized, third-generation family business based in Gevelsberg in Germany. The company’s product range has been gradually expanded over the past 75 years. As the product range has grown, the number and diversity of customers has also increased. Over time, the company has developed a client base from all branches of industry beyond the borders of Germany and Europe.
The Paul Hedfeld GmbH supplies its international customer base with spare parts and new systems for bucket elevators, screw conveyors, slat conveyors, silo systems, trough chain conveyors and customized special constructions.
Paul Hedfeld GmbH defines itself as a very customer-focused company and thus manages to set itself apart from its
competitors. A smooth and fast flow of all business processes serves as a success factor for customer satisfaction. The stock of many important spare parts ensures fast delivery to customers and can minimize their unforeseeable downtimes of conveyor systems. If a customer wants to open up a new conveying route or replace an existing system with a new one, Paul Hedfeld GmbH is an ideal contact for projects of any status.
The company employs experienced and competent engineers in its sales department who can deal with technical problems and issues when planning new systems. The installation of new systems and spare parts can be carried out by skilled fitters. Paul Hedfeld GmbH provides customers with all services from a single source, if desired.
In addition to its customer-oriented focus, the company’s competitiveness is ensured by constantly adapting to the market in order to enable customers to
transport their bulk goods without issues. This includes constantly adapting the products to the regulations to which the customers are subject. An example of this is the adaptation to the ATEX directive for the prevention and avoidance of explosions.
Paul Hedfeld GmbH considers it essential to adapt to trends and changes
Paul Hedfeld GmbH has already implemented many projects in the past. Below are some examples of past and current projects from various branches of industry to go with the pictures:
Shown in pictures 1, 2 and 3: the construction of a silo system is intended to provide the customer with an intermediate buffer between kilning and sterilization. In addition, the conveying capacity is increased through the use of various trough chain conveyors and a belt bucket elevator. The silo cells and parts of the conveyor
technology were enclosed in a cladding.
Pictures 4, 5 and 6 illustrate when Paul Hedfeld GmbH renewed the sand/gravel intake of a concrete plant. Parts of the receiving hopper were renewed, a new belt bucket elevator and a oscillating conveyor were installed and a head platform was fitted.The new conveying capacity is 160tph (tonnes per hour) of sand or gravel.
Transporting bulk goods (see pictures 7 and 8) does not always have to be spacebound, as the mobile loading auger shown in the pictures demonstrates. It can be moved with a forklift and can be swivelled and adjusted in height and depth on the spot. The solution was built for a customer to load malt into a 40ft container. A conveying capacity of 40tph is possible with
In pictures 9, 10, 11 and 12, there is an example of an interesting current project — the development of a germination box for the vault-basement of a German specialty brewery. The dimensions of 19x2m enable the processing of two times five tonnes of green malt. The raisable cover ensures an optimal germination process and atmospheric condition. The entire system is made of V4A and operates in an energy and water-optimized way. Due to the modular system of the germination box, this solution is easily adaptable to other conditions and can therefore also be purchased by other prospective customers. Another special feature of the system is the pneumatic discharge using a patented screw conveyor.
Customer-specific problems (see picture 13) require individual solutions. In some cases, maximum effects can be achieved by making minimal changes to the overall system. This case is represented by the addition of brushes to the screw flights. In this particular case, a customer had problems with material residues in his screw conveyor. By fitting the brushes, this problem could be solved quickly and costeffectively.
Paul Hedfeld GmbH will maintain its focus in the future and will continue to implement interesting projects with full commitment and will be available as a reliable partner for the supply of spare parts to customers.
When it comes to modern material handling, efficiency remains a primary focus. However, as industrial demands continue to evolve, there is a growing need for equipment that not only optimizes performance but also prioritizes workplace safety, operational comfort, and environmental sustainability. The Vortex Aero-Slide, with its air-gravity conveyance technology, addresses these challenges directly, offering unmatched versatility for industries working with lightweight, fluidizable dry bulk powders such as cement, fly ash, and trona. Beyond its functionality, the Aero-Slide sets itself apart in areas often neglected by traditional systems—including dust control, noise
reduction, and adaptability in extreme environments.
One of the standout benefits of the Vortex Aero-Slide is its significant contribution to workplace safety. The system’s dust-tight design ensures that fine particles remain securely contained during the transfer of materials. Handling bulk powders such as fly ash inherently carries risks due to the potential release of harmful particulates into the air. Exposure to these substances can pose severe health risks, including respiratory issues and long-term occupational illnesses. By effectively sealing
off transferred materials, the Aero-Slide safeguards workers’ health and maintains a cleaner environment inside production facilities. This feature is particularly critical in sectors such as cement manufacturing and chemical processing, where handling powders can involve substances that are abrasive, hazardous, or potentially toxic. Additionally, the enclosed design reduces the risk of material spillage, thus minimizing clean-up efforts and ensuring compliance with workplace safety and regulatory standards.
Industrial environments often suffer from excessive noise levels, largely caused by machinery with moving components. Prolonged exposure to elevated noise can result in hearing loss and place undue strain on operators on the production floor. The Vortex Aero-Slide takes a proactive approach to this issue by utilizing a remote fan or blower system that powers its lowpressure, gravity-assisted conveyance.
Unlike conventional systems such as screw conveyors, which rely on mechanical parts prone to high frictional wear, the Aero-Slide operates with minimal acoustic impact. Its silent performance fosters a healthier and less disruptive workspace for employees, enabling improved concentr-
ation and reducing fatigue during long shifts. Noise reduction also benefits facilities located near residential areas or urban settings by helping organizations comply with environmental noise regulations.
The adaptability of the Vortex Aero-Slide in challenging environments is another feature that distinguishes it from traditional conveying systems. Constructed using durable materials, such as various steel options and reinforced porous media, the conveyor thrives in conditions that would typically cause failures in other systems.
For industrial sites exposed to extreme heat, cold, or fluctuating temperatures, the Aero-Slide maintains its operational integrity. Its ability to handle material temperatures of up to 400°F (205°C), with appropriate modifications, broadens its applications in high-heat industries such as manufacturing and mining. The conveyor’s robust design also ensures reliable performance in outdoor installations, with features like a rain ledge to prevent precipitation from infiltrating the system and causing disruptions. This resilience makes the Aero-Slide an excellent choice for remote mining facilities with limited infrastructure or chemical plants where environmental conditions can be particularly volatile. With fewer maintenance requirements and the ability to support prolonged operational cycles, the Aero-Slide facilitates consistent production under extreme conditions and isolated work sites.
The Vortex Aero-Slide’s design goes beyond safety and adaptability to emphasize a strong commitment to sustainability. The air-gravity conveyance process significantly reduces energy consumption, relying on just one low-power fan or blower to function effectively. This efficiency is in stark contrast to conventional systems, which often require motors, gearboxes, and belts that consume considerably more energy over time. Additionally, the Aero-Slide’s dust-tight design prevents environmental contamination, while its long service life and minimal maintenance needs reduce the frequency of part replacements. These factors combine to lower operational costs and decrease environmental impact —aligning with the increasing
global emphasis on sustainable industrial practices.
To illustrate the versatility of the Aero-Slide, consider a remote mining operation tasked with handling trona powder in arid, hightemperature conditions. The Aero-Slide can transfer bulk powders across long distances using minimal energy. Its sealed, dust-tight construction not only protects operators from exposure to airborne particles but also safeguards local air quality in environmentally sensitive areas.
Alternatively, within chemical processing plants handling corrosive materials, the stainless steel option enhances durability, enabling the Aero-Slide to withstand harsh conditions. Even in highly regulated industries such as food production, where hygiene standards are critical, the
Aero-Slide’s low-maintenance and dust-free design offers a cleaner, more reliable method for handling powdered ingredients.
The Vortex Aero-Slide illustrates how modern material handling equipment can — and must — go beyond simply moving materials from one point to another. Safety, operational comfort, and environmental stewardship are essential elements of today’s industrial solutions, and the Aero-Slide delivers across all these dimensions. For facilities striving to reduce risks, enhance efficiency, and adapt to extreme environments, this innovative system represents the future of material handling. The Aero-Slide is more than just a conveyor — it is a dependable partner for creating safer, quieter, and more sustainable workplaces in preparation for the industries of tomorrow. DCi
Bulk handling equipment specialist Loibl offers conveyor systems as well as shiploading and unloading equipment for port handling. It provides efficient solutions that enable the smooth transportation of materials from the pier edge to the storage and point of use.
Loibl’s high-performance loading and unloading equipment is specially developed for port handling. They can be used to transport large quantities of bulk goods quickly and safely. It also offers a wide range of conveying solutions that meet the individual requirements of each port. These include feed hoppers and hopper cars, chain conveyors, screw conveyors or belt conveyors that enable the continuous transfer of bulk goods over long distances.
For HOFOR, the largest utility company in Denmark, Loibl designed an
economically efficient, individual solution for the transport of biomass (wood chips) from the port to the incineration plant at the end of 2019. HOFOR supplies around 20% of the entire Danish population with water, heat, electricity and gas. Loibl supplied a facility with a total weight of around 390 tonnes of technical equipment. It forms the interface between ship and stationary conveyor technology.
The supply included two massive hoppers with an octagonal opening and a dust return wall attached. This special shape already reduces the amount of dust during the wood chip loading. Under the hoppers there are trough chain conveyors (LASHCHAINCON®) in a particularly heavy design and with a clear width of 2,000mm. 800 m³/h of conveyed goods are withdrawn from each of these
The feed hoppers are open at the top; this reduces the formation of an explosive atmosphere and ensures pressure relief in the event of an explosion. The material is withdrawn from the hoppers in the upper run of the trough chain conveyor below. A dedusting system automatically sucks up the dust generated during transshipment in the feed hopper and at the subsequent transfer points. Heavier dust particles are reliably transported away with the conveying flow.
Each of the so-called hopper cars removes a total of 1,600m³/h of material. In addition to the dust return, the hopper cars are equipped with dry extinguishing lines including spraying in the feed bunker and filters. In the event of a fire, the water is fed in by the local fire brigade with the
dry fire line on the hopper car. In addition, a fire hose can be connected to a separate riser if necessary to extinguish fires on the hopper car. For cleaning, there are suction and wet cleaning lines on the hopper car, to which the operator can connect the corresponding equipment.
The hopper cars are coupled with the harbour cranes. This means that they can be moved individually and to any ship unloading position on the pier. During the unloading pauses, the clamshell bucket and multi-section grab can be safely placed on the hopper car.
Extensive engineering v Production in Straubing, Bavaria v Delivery of selected components v Installation and commissioning on site v Conveyor technology for biomass v transport: feed hoppers, movable steel construction, LASHCHAINCON®: discharge trough chain conveyor, control cabinet including cabling, dry fire line, suction and wet cleaning line, filter system (dedusting) including pressure relief device
Combined heating and power plants are gaining in importance in connection with the striven fossil-fuel phase-out. Many power plant operators are already reacting to the ambitious climate targets of politics and are gradually converting their systems to renewable energies.
The transition process works with combined firing from fossil fuels and renewable raw materials, mainly wood. In the long term, there should be a permanent switch to the combustion of renewable energies. In this phase it needs an experienced partner who reliably supports the energy producers and industrial users with the changeover.
In the Port of Copenhagen, 3,200m³/h of biomass are handled daily at the Amagerværket power plant. The amount of dust that arises during loading increases the risk of ignition.
With more than 60 years of experience in individually conceptualized bulk materials transport and as a competent partner in the field of fire-endangered and explosive bulk goods, Loibl developed an innovative, ATEX-compliant conveying concept that more than lived up to the expectations of the largest Danish energy supplier.
Bulk cargo handling plays a vital role in global trade, facilitating the critical transport of essential materials across various industries. At the heart of this process, hoppers play a critical role in maintaining seamless supply chains at ports. Mobile Conveying Services Pty Ltd (MCS) has revolutionized bulk cargo logistics by designing patented specialized low-profile mobile bulk hoppers with conveyor feed that enhance safety, efficiency, weight accuracy, and reliability and also address a growing environmental issue with dust control.
Established in Brisbane in 2007, MCS is a private Australian company that has emerged as a highly successful supplier of equipment for the bulk materials handling industry. The company supplies specialized equipment, skilled labour, and expert management to customers across Australia and the Pacific region. With a strong reputation built around its fleet of Mobile Conveying Equipment and Telebelts, MCS delivers world-class handling solutions tailored to the unique demands of bulk cargo logistics.
Efficient bulk cargo handling requires versatile, high-performance equipment capable of operating in diverse environments. MCS’s mobile hoppers — including its dust extraction model — are designed to allow for ease of transfer to and from
berths for the handling of bulk cargo discharge and then can be taken away from berths and stored offsite ensuring critical berth space is not used up for storage of stevedoring equipment.
A key advantage of MCS’s mobile hoppers is their adaptability being able to load direct to trucks or feed customers fixed conveyor systems. Another feature is the ability to batch weigh cargo that is loaded into trucks or conveyor systems. Truck drivers can watch cargo being loaded into their vehicles via an LCD screen which also displays the weight of product being
transferred safely into the truck units. Another key feature is the enhanced safety element of grabs not travelling over trucks and therefore eliminating a constant risk element that is a regular issue. MCS hoppers have been utilized at two of Australia’s major manufacturing plants helping ensure critical bulk product reached the plants and ensure production schedules were maintained. By integrating this advanced technology and safety improvements, MCS ensures that bulk materials being discharged from vessels are transferred with care and precision.
On top of the significant features of the MCS hopper and taking into account the global focus on environmental controls MCS designed a bulk cargo hopper that significantly improves the management of dusty cargoes, reducing airborne particles from dispersing into nearby communities. This commitment to high-quality, environmentally enhanced equipment enables MCS to deliver cutting-edge solutions that enhance environmental protection, operational efficiency, and safety.
As global trade continues to drive advancements in cargo handling, the demand for innovative bulk cargo solutions grows. MCS remains at the forefront of this evolution, delivering cutting-edge bulk hopper systems that prioritize environmental sustainability, safety, and supply chain efficiency.
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Brad Pronschinske, Global Air Cannon Product Manager at Martin Engineering, explores options for preventing blockages in silos and hoppers using flow aids.
In all bulk processing systems there are places where materials need to held up, stored and channeled into the next stage of production. And even well-designed systems can succumb to the problems of materials clinging to the inside walls of silos, bins, hoppers and chutes.
Once material starts to stick, the buildup is generally fast and dense, slowing the flow, causing spillages and secondary blockages, and eventually resulting in unscheduled downtime. To make matters worse, the temptation to find a quick way to remove the blockage, without the proper risk assessment, safe access, tools or training, can lead to workers putting themselves at risk.
This is where flow aids come in, devices specifically engineered and installed to promote material flow, clear buildups and prevent clogging, avoiding costly downtime and reducing the associated safety risks. A variety of flow aid technologies are available but to know what technology will work best for a specific application, the first step is understanding how, where, when and why clogs are happening in a particular vessel. Then the next step is designing a system that eliminates the need for any worker involvement in clearing the blockages with the installation and activation of the right flow aids.
CAPACITIES, CHARACTERISTICS AND CLOGGING
Whether the container is a silo, hopper, bin or something else, understanding the
function and maximum load of a vessel is vital. Equally important is an appreciation of the properties of the materials passing through, including moisture content and temperature, plus the effect of atmospheric conditions. Wide variations in the size and shape of particles also affects the flow characteristics. Failure to consider these and other factors can lead to suboptimal designs that increase the likelihood of buildups and clogging.
Further, if a hopper is not designed to carry the right material load at full capacity, then a sudden surge of material or a clog can lead to potential dangers. And even if a hopper or silo is engineered properly, repeated abrasion from loading over years can cause the vessel walls to wear thin,
Bulk materials will always need to be stored and clogging is common (all photos: copyright ©2025 Martin Engineering).
decreasing their capacity to contain the weight, and potentially affect structural integrity, increasing the risk of a serious event.
There are numerous reference guides that explain vessel loading for the right design to be determined, including load factors such as:
Dead load: the total weight of the v structure, including attached components and equipment supported by the structure.
Live load: forces exerted from the v stored material, including high and low pressures caused by flow, plus anything independent of the structure such as snow, positive and negative air pressure, wind or seismic load, and any
1 – The discharge point generally matches the geometry of the vessel.
forces from materials stored against the external wall.
Thermal load: caused by temperature v differences between the inside and outside faces of the wall.
Settling load: forces from uneven v settling of the structure.
So the weight, size and type the material, load velocity, plus direction and distribution, structural design of the vessel, as well as factors like weather can all play a part in clogging and overloading. And the moment the clogged material is discharged, the force of the surge can also overwhelm the structure, gate, skip or conveyor onto which it is flowing, so understanding the weight of the material in the clog itself is important too.
Discharge points come in varying shapes, depending on the vessel and the material flow characteristics [Fig 1]. Plant manufacturers carefully choose discharge point shapes based on a series of load and flow factors. Spouts that are narrow, such as those found on conical or pyramidal shapes, direct flow in a vertical column
Hammering on the outside of a hopper is rarely a long-term solution to materials clogging in hoppers and other containers.
either into a chute or specific loading area. Slotted spouts, like those found on the wedge or transition shapes, typically distribute material in a narrowly defined line for loading onto conveyors or into containers (trains, trucks, etc.)
The shape of a vessel should match that of the discharge point or it will be prone to clogging. The slope angles in discharge point geometries can also contribute to clogging, depending on material characteristics, the specifications of the application or the placement of the vessel.
Discharge points can feature gates or grates that stop or help to separate the
material. Gates, for example, halt material flow for incremental filling of rail cars or a truck body. Grates can be used to slow or direct the flow of material when loading onto a conveyor. Either way, operators often find that these devices can exacerbate clogging by stopping or slowing material at the structural choke point of the vessel.
Once a clog has been detected, there are several unsafe practices that, at the time, may seem like a quick and harmless solution, but frequently cause injuries and
are even known to cause fatalities.
One unsafe but common method is beating the vessel walls with mallets or other heavy objects to loosen adhered material. Besides the health and safety risks, over time, the more the walls are pounded, the worse the situation becomes, as the bumps and ridges left in the wall from the hammer strikes will form ledges that provide a place for additional material accumulations to start.
Another hazardous yet popular practice is poking or lancing underneath the clog at the discharge point. This can result in a sudden surge of falling material, burying or crushing the worker(s) below. Physical lancing from above is also common, often with makeshift platforms that allow access but provide little protection should a worker slip and fall into the vessel.
Air lancing the clog from the mouth of the vessel at the top can be an effective option, but only when guardrails are fitted, or a safe access platform is used. Of course, the reach of the lance and the pressurized air stream must match the size of the vessel and the clog. And again, unless a harness is worn, workers could still fall in trying to get the lance down to the clog, even if guardrails are present.
Perhaps the most prevalent cause of worker injuries is entry into the vessel. Along with potentially sinking into the material, especially in the centre, the silo or hopper contents could be ‘bridging’ and suddenly release.
If a worker enters the vessel and stands on the fragile bridge or on a buildup to the side, a sudden discharge could pull the worker into the cavity causing serious injury or engulfment.
These unsafe situations and behaviours
One of the main advantages of flow aids is that plant operators gain a level of control over material flow that is not possible any other way.
by
material
Air cannons deliver a controlled burst of compressed air to dislodge material buildup.
As the term implies, flow aids are components or systems installed to promote the flow of materials through a silo, bin, hopper or chute, whilst controlling buildups, dust and spillage. Flow aids come in a variety of forms, including rotary and linear vibrators, high- and low-pressure air cannons and aeration devices, as well as low-friction linings and optimal chute designs, to encourage the most efficient flow of bulk materials.
These solutions can be combined in any number of ways to complement one another in an integrated system to improve overall productivity. Flow aid devices can be used for virtually any bulk material or environment, including hazardous duty and extreme temperatures.
When employing flow aids, it’s critical that the hopper or silo structure is sound and the flow aid device(s) are properly sized and mounted, because their operation can exert additional stresses on the
A
Strategic positioning not only relieves buildup, but improves material flow.
structure. A well designed and maintained vessel will not be damaged by the addition of correctly sized and mounted flow aids. It’s also important that any flow aid device is used only when discharge gates are open and material can flow as intended. By far the best practice is to use flow aids as a preventive solution to be controlled by timers or sensors to avoid material buildup, rather than waiting until material accumulates and begins to restrict the flow. Using flow aid devices in a preventive manner not only reduces the chance of clogging but also enhances safety and can even save energy.
The age-old solution for breaking loose blockages and removing accumulations from chutes and storage vessels was to pound the outside of the walls. A better solution is the use of engineered vibration, which supplies energy precisely where needed to reduce friction and break up potential accumulations to keep material
moving to the discharge opening, without damaging the chute or vessel. The technology is often found on conveyor loading and discharge chutes but can be effectively applied to other process and storage vessels, including silos, bins, hoppers, screens, rail cars, feeders, cyclones and heat exchangers.
Another highly effective solution for eliminating material accumulation in chutes and vessels is the low-pressure air cannon, pioneered and patented by Martin Engineering in the 1970s. It uses a plant’s compressed air system to deliver a powerful and carefully timed blast to dislodge buildups. Air cannons can be mounted on metal, concrete or even wooden surfaces as long as they are structurally sound. The basic components include an air tank, a fast-acting valve with a trigger mechanism and a nozzle to distribute the air in the desired pattern to clear the accumulation most effectively.
The sudden blast of air released by the valve on an air cannon is directed through an specially designed nozzle, which is strategically positioned in the chute, tower, duct, cyclone or other location. Often installed in an array of several air cannons and precisely sequenced for maximum effect, the devices can be timed to best suit individual process conditions or material characteristics. The air blasts help break down material accumulations before they become problematic, allowing materials to resume normal flow. In order to customize the air cannon installation to the service environment, specific air blast characteristics can be achieved by manipulating the operating pressure, tank volume, valve design and nozzle shape.
In the past, when material accumulation problems became a recurring issue in hardto-access areas like preheater system, processors would have to either limp along until the next scheduled shutdown or, more likely, endure expensive unplanned downtime to lance the clogged buildups. That used to cost businesses hundreds of thousands of dollars per day in lost production. Nowadays, such is the importance of keeping material flowing that vessels of all kinds now feature mountings
major areas of buildup helps determine the number and placement of air cannons.
so that devices such as air cannons and vibrators can be fitted safely with relative ease.
Given the demands and complexities of processing bulk materials, buildups and blockages in silos, hoppers and other vessels should be banished with engineered solutions such as vibration, air cannons and other flow aids. The key to success lies in selecting the appropriate flow aid
technology based on material properties, vessel design and operating conditions. Moreover, proactive and preventive use of these solutions, rather than reactive measures, is proven to help maintain optimal performance and can even extend
the lifespan of storage and transfer equipment. As processing plants continue to prioritize efficiency and worker safety, investing in well-designed flow aid systems is a necessity. By embracing such innovations, producers can achieve smoother operations, maximize throughput, and create a safer working environment, ensuring that materials move through the process without unnecessary interruptions.
The production team at a cement plant in Arizona, USA was experiencing regular clogging in the site’s main limestone silo and weekly downtime was becoming an issue. Recent excessive rain meant the limestone quarried nearby had elevated moisture levels, exacerbating the situation.
Air cannons had already been used successfully elsewhere in the cement production process, so operators were confident in their performance as a solution. Five 70-litre (88 lb/40kg) air cannons were strategically placed around the limestone silo. Installed with a 4-inch (101mm) valve, three were placed on the lower incline of the cone at a 30º downward angle against the 60º slope in the 6 and 12 o’clock positions. In the
3 o’clock position, one air cannon was situated at the two-foot-wide shaft, and another was added to the upper silo to encourage material to loosen. The cannons use a ‘positive-acting’ valve that is triggered by a solenoid located a safe and convenient distance — up to 200 feet (61 metres) — from the vessel. That also means it fires only in response to a positive surge of air sent by the solenoid, eliminating the risk of an accidental discharge.
Since the installation, there has been no unscheduled downtime due to clogging, which has greatly increased productivity, especially through heavy weather periods. When buildup is detected, workers no longer need to get close to the area to resolve it, improving safety and reducing the time required to clear and maintain the silo.
Brad Pronschinske, Global Air Cannon Product Manager at Martin Engineering is responsible for the development and management of Martin Engineering’s air cannon products and vibration systems as used to improve bulk material handling in applications around the world. He joined Martin Engineering in 1998 as a Product Specialist–Air Cannons and became Global Product Manager–Air Cannons in 2005 and continues in that role today. Pronschinske
holds many US and International patents on air cannon models with additional patents on nozzles for air cannon systems. He has a BS in Electronics Engineering from Hamilton Technical College in Davenport, Iowa.
Martin Engineering has been a global expert in bulk material handling for more than 80 years, continuously developing new solutions to make high-volume conveyors cleaner, safer and more productive. The company’s series of Foundations™ books is an internationally recognized resource for safety, maintenance and operations training — with more than 22,000 print copies in circulation around the world. The 500+ page reference books are available in several languages and have been downloaded thousands of times as free PDFs from the Martin website. Martin Engineering products, sales, service and training are available from 18 factoryowned facilities worldwide, with whollyowned business units in Australia, Brazil, China, Colombia, France, Germany, India, Indonesia, Italy, Kazakhstan, Malaysia, Mexico, Peru, Spain, South Africa, Turkey, the UK and USA. The firm employs more than 1,000 people, approximately 400 of whom hold advanced degrees.
Global Manufacturing, Inc. is a renowned American manufacturer of industrial vibrators and air blasters, specializing in solutions that ensure consistent material flow in hoppers, bins, and trailers. The company works closely with industrial product distributors and OEMs that design and manufacture hopper systems, providing end-users with effective flow solutions
through its extensive distributor network and OEM partnerships. Additionally, Global Manufacturing has established a strong presence in the maritime sector, working with self-unloading ships and shipbuilders to enhance bulk cargo handling efficiency.
ENHANCING BULK MATERIAL FLOW WITH VIBRATORS AND AIR BLASTERS
Inconsistent or blocked material flow within hoppers and bins presents a major bottleneck in industrial and shipping operations. While optimal flow can often
be achieved in the hopper design phase, space constraints and varying material properties can make mass flow difficult to maintain. In such cases, the simplest and most cost-effective solution is the addition of a vibrator (see Picture 1). Vibrators are highly effective for moving a wide range of bulk solids, including minerals, aggregates, powders, and wood pellets. However, some materials, such as wood chips, require an air blaster to provide additional force. Air blasters are also indispensable for clearing residual material from bin walls, seams, and other accumulation points (see Picture 2).
Global Manufacturing, Inc. is committed to continuous product improvement, ensuring that its vibrators and air blasters deliver superior performance, longevity, and ease of use. Recent advancements include:
Enhanced Piston Vibrators: the v Yellow Jacket™ (YJ) piston vibrator line is engineered to outperform conventional designs while reducing weight by 55–68%. Despite its lighter construction, the YJ vibrator produces equal or greater force — sometimes doubling that of competing models. Additionally, it requires only a single mounting bolt, significantly simplifying installation (see Picture 3).
Customizable Design Series: v recognizing that no single vibrator suits all applications, Global Manufacturing offers its Design Series that allows customers to tailor units to their specific needs. Options include pneumatic, hydraulic, and DC electric motors, multiple mounting configurations, and adjustable weights to fine-tune force output. With variable flow control for pneumatic and hydraulic models, users gain nearly limitless force and frequency settings within each vibrator’s operating range.
Manufacturing Innovations: cost v reduction and supply chain efficiency remain critical in today’s economy. While traditional methods focus on scaling production, Global Manufacturing pursues process improvements that reduce laborintensive touchpoints. By minimizing wear parts, offering easy-to-install repair kits, and ensuring readily available replacement components, the company prioritizes long-term cost savings for its customers.
Customer-Driven Enhancements: v beyond internal innovations, Global
Manufacturing actively integrates customer feedback into product development. By closely monitoring market trends and purchasing cycles, the company adapts its offerings to meet evolving industry needs. Feedback from the ship industry and the sea-salt environment had Global provide epoxy-coated (both inside and out) vibrator options to weather that environment (Picture 5).
Education is central to Global Manufacturing’s mission, helping customers and endusers optimize their operations while reducing maintenance costs. The company collaborates with application engineers to refine system designs, ensuring maximum material flow efficiency.
This commitment has led to major contracts in the shipping industry, where its air blasters and vibrators are increasingly used in self-unloading ship offload solutions which enhances the need for service and distributors in ports (see
Picture 4).
To further support its customers, Global Manufacturing focuses on educating distributors and OEMs on proper vibrator selection and application. The company’s training emphasizes:
1. Identifying when and where a v vibrator is needed.
2. Selecting the most effective and v cost-efficient unit.
3. Understanding material behaviour v to optimize force and frequency settings.
Global Manufacturing has also developed a Rotary Vibrator Calculator, available on the company website, allowing users to quickly evaluate their applications and receive tailored vibrator recommendations. Additionally, the company offers a wealth of online resources, including ‘How-To’ guides covering scientific principles, proper mounting techniques, best usage practices, and maintenance guidelines. Use of the online contact forms can easily get the experts involved in solving any material flow issue.
SUPERB WARRANTY AND CUSTOMER SUPPORT
Global Manufacturing, Inc. stands behind its products with the best warranty in the industry—a Lifetime Warranty. This commitment underscores the company’s dedication to quality, reliability, and customer satisfaction.
By continually advancing its products, educating its customers, and innovating in response to industry demands, Global Manufacturing, Inc. remains at the forefront of bulk material handling solutions for the dry cargo sector.
QUARRY MINING LLC designs and manufactures screening and crushing plants in compliance with European standards while adhering to the same safety standards and features that you would expect from European equipment. Quarry Mining LLC
(QM) is certified for quality management with ISO Certificate 9001:2008 and for environmental management with ISO Certificate 14001:2004 from the German Technical Inspection Association TÜV Rhineland/Germany. These certifications include the continuous integration of all upgrades. Located in the United Arab Emirates, QM can supply high-quality plants at very competitive prices.
Bulk handling hoppers are key components for bulk handling applications.
Every process needs to start with something, and in most of the applications, that’s a hopper because it’s very inefficient to feed a conveyor belt, etc., directly with a shovel loader. Hoppers are made to receive materials, store materials, and discharge them again like a funnel. This principal material can be transferred e.x. from a 5m width dump truck to a 1m width conveyor belt. Hoppers are versatile in terms of opening sizes, storage volume, and discharge principle. The wall angle plays a key role in the design concept and differs from material and equipment application type. Sticky material requires a very steep angle to prevent material from staying inside the hoppers. In this regard, the liners and their friction values are also essential. Compared with silos, hoppers are always open to the top. Special dust suppression systems can be used to avoid dust evaporation while filling.
Quarry Mining has built more than 50 hoppers over the past ten years, not one like the other, always individually designed for its application and material, from 1m³ up to 1.500m³. One with the biggest capacity was for a 4.500tph (tonnes per hour) primary crushing plant. Equipped with a mist water dust suppression system, the latest environmental requirements have been fulfilled. Able to feed it from three sides, each dipping point to handle dump trucks with 120t payload. It’s a massive build that handles material sizes up to 2m in diagonal of limestone.
The hopper is built directly into the rock of the quarry and uses the natural rock face as three side walls. The fourth side is made of a massive steel structure to withstand material loads. Discharged by a horizontal moving push feeder, the material is fed directly to one of the biggest jaw crushers in the world with an opening
width of 2,100mm. The material funnel ratio, therefore, is 6:1, from 12m width to 2m width.
A totally different application is the design of the feed hopper of a small test plant for a renowned university. The feed size of 0–10mm is very small, and due to the requirement of being an R&D plant and its small feed capacity of 70tph, only the hopper is filled directly with the shovel loader. This makes handling easier. To allow a reasonable storage capacity and to install a discharge feeder underneath, the hopper stands on four support columns, and the shovel loader reaches the hopper edge to tip its load via a concrete ramp. Two extended side walls ensure no material is falling off while tipping the material. The vibration feeder underneath discharges the material onto a conveyor belt, making the funnel ratio 9:1, from 4.5m hopper width to 0.5m conveyor belt width.
Hoppers play a critical role in dry bulk material handling systems. Bulk materials such as grains, cement, sand, and coal can be stored and dispensed using various types of hoppers. They control material flow and reduce the risk of clogging, making them essential in industries such as mining,
uring. With its expertise in sustainable and cost-effective bulk material handling solutions, Polimak provides reliable hopper solutions to meet the specific needs of various industries.
Efficient material storage: hoppers v serve as a temporary storage space for bulk materials before they are transferred to the next piece of
equipment.
Controlled discharge: hoppers ensure v a steady and controlled flow of dry bulk materials, minimizing waste and spillage.
Preventing material blockages: well- v designed hoppers reduce clogging issues like bridging and ratholing. Enhancing process automation: by v connecting with other equipment like conveyors and feeders, hoppers provide a more effective solution.
Optimizing space usage: space-saving v designs allow for optimal utilization of available space, ensuring efficient storage even in limited areas.
Handling a multitude of materials: v hoppers are suitable for handling powders, granules, aggregates, and a wide range of other dry bulk materials in different industrial applications.
Customizable design: Polimak’s v hoppers can be produced in a variety of shapes, sizes, and discharge mechanisms to accommodate the specific needs of different applications.
POLIMAK’S RELIABLE BULK HANDLING
SOLUTION: MOBILE TRUCK LOADING
SYSTEM WITH FRONT END LOADER HOPPER Polimak’s mobile truck loading systems with an integrated loader hopper facilitate the efficient transfer of materials from wheel loaders to bulk trucks. The system consists of a mobile platform, a front-end
loader hopper (or a big bag loading unit, depending on the customer’s needs), a loading screw, a telescopic loading chute together with a dust collector.
Operation of the mobile truck loading system is as follows:
1. POSITIONING THE SYSTEM
The mobile system is placed near the v bulk truck to be loaded.
The screw conveyor is lifted to a 45º v angle using automatic screw jacks.
2. MATERIAL LOADING INTO THE HOPPER
A wheel loader discharges material v into the system’s hopper.
A heavy-gauge hopper withstands v incidental contact with the loader.
A high-capacity screw conveyor runs v continuously as the loader replenishes material.
Optional air jets and vibrators aid v material flow inside the hopper.
3. MATERIAL TRANSFER & LOADING PROCESS
An inclined screw conveyor transfers v material from the hopper to the truck. Material is discharged into the bulk v truck through a loading bellows.
4. DUST COLLECTION
A dust collector prevents dust v emission during the loading process. It is connected to both the loading v bellows and the hopper. Filters the dust and return it to the v hopper via pulse jet valves.
5. LOADING BELLOW OPERATION
The loading bellows are lowered until v they reach the bulk tanker inlet.
A polyurethane-coated discharge cone v ensures a sealed connection, preventing dust escaping.
Material flows freely through the inner v side of the loading bellows.
6. AIR EVACUATION & LEVEL MONITORING
A built-in dust collector removes v trapped air inside the tanker to improve material flow.
A level sensor at the bottom monitors v the fill level.
Loading stops automatically when the v bulk tanker is full.
After product filling is complete, the v loading bellow retracts to the top position.
POLIMAK : RELIABLE AND INNOVATIVE HOPPER SOLUTIONS FOR DIVERSE INDUSTRIES
Polimak’s hopper solutions, integrated with innovative and complex dry bulk material handling systems like the one described above, are designed for a wide range of applications.
With 45 years of experience and technical expertise, Polimak provides sustainable, durable, high-performance, safe, and cost-effective solutions for a wide range of industries, including food, chemicals, mining, plastics, and cement. DCi
with modern, sophisticated grain handling and storage systems
Chief Agri, a division of Chief Industries, Inc., specializes in the design, manufacture and sale of grain storage systems around the world. With over 60 years of experience, Chief offers customers a wide range of products and the expertise to serve their individual needs. Chief offers everything needed for a complete grain storage system, including steel grain bins, grain handling (belt conveyors, chain conveyors and bucket elevators) conditioning equipment (fans, heaters and floors)
along with square feed mill storage bins.
Chief manufactures most of the major equipment and accessories that go into a storage facility and offers some of the most comprehensive warranties in the industry. Chief offers more than 300 standard grain bins and hopper tank sizes with bins available up to 42.4 metres in diameter and storage capacities up to 33,000 metric tonnes.
Chief silos offer heightened efficiency and more competitive pricing, which
achieves Chief’s ultimate goal of reduced grain storage costs. Combined with its material handling line and Caldwell aeration line, every Chief customer can be assured of a top quality complete system.
Technical support from Chief doesn’t end with the sale. Chief strives to deliver the professional guidance customers need to construct the best possible system to meet their operational needs. Chief works hard to live up to its motto: “Trusted. Tested. True.”
Egypt’s General Company for Silos and Storage (GCSS) has launched a state-ofthe-art terminal at Port Said to bolster the country’s grain storage and distribution infrastructure. With Egypt importing around 14 million tonnes of wheat annually from major suppliers such as Russia, Ukraine, France, the US, and Australia, efficient and reliable unloading systems are crucial for maintaining supply chain stability. A key component of this new terminal is the integration of two NEUERO MULTIPORT M600 pneumatic shipunloaders, each capable of handling up to 600 tonnes per hour. These advanced systems ensure smooth and efficient unloading of essential agricultural commodities such as wheat, soybeans, barley, and corn.
NEUERO, a leader in pneumatic shipunloading technology, has supplied two M600-30-SF-MV-HHW15 unloaders to the Port Said Terminal. These high-capacity machines are mounted on rails and powered via power cable drums, ensuring seamless operation along the quay. The new facility is designed to handle Panamaxclass vessels, efficiently transferring grain to two quay conveyors or directly onto trucks for further distribution. The M600’s role in streamlining logistics is pivotal to Egypt’s strategic initiative to maintain robust grain reserves, mitigating the effects of market fluctuations and securing food supply for the nation’s 100 million people.
The unloading process starts with the deployment of the M600’s 30-metre horizontal boom, which extends over the ship’s hold. The Auto Dipping System
(ADS) ensures precise control of the suction nozzle, optimizing its depth for maximum efficiency. As the nozzle is lowered into the grain cargo, the pneumatic suction system draws the material through the pipeline, minimizing dust emissions and ensuring a clean operation.
The system’s partially automated
operation enables efficient movement within the hold, systematically covering all areas to achieve complete unloading. Operators monitor the process via the fully electronic control system, adjusting parameters as needed to maintain optimal flow rates.
At the heart of the M600’s performance is its specialized suction nozzle, designed for both high efficiency and operational flexibility.
The ADS feature allows the nozzle to automatically adjust its position based on real-time material flow data, reducing operator intervention and ensuring continuous, even unloading. This automation enhances speed while preventing blockages, which is especially crucial for high-volume grain handling.
As the grain is lifted, it travels through the unloader’s pneumatic system and is
discharged onto the designated conveyors or directly into trucks. This process ensures minimal grain loss, reducing handling time and maximizing throughput. The system’s design also prevents grain degradation, preserving quality from ship to storage.
The M600 is equipped with several innovations that enhance both safety and maintenance:
Boom-to-ground feature: the v horizontal boom can be fully lowered to the ground, facilitating easy and safe maintenance. This also serves as a high-wind protection feature, securing the equipment during extreme weather conditions.
15-tonne auxiliary winch: this v allows for easy handling of auxiliary equipment and components, further enhancing operational efficiency.
Partially automated control: the v ADS and intelligent movement system enable optimized unloading with minimal manual intervention, improving both safety and speed.
The Port Said Terminal, funded by the Government of Egypt (GOE) & OPEC Fund, represents a critical step in Egypt’s long-term strategy for food security.
By incorporating cutting-edge technologies such as NEUERO’s M600 pneumatic unloaders, the facility ensures efficient handling of bulk grain imports, safeguarding reserves against price volatility and supply chain disruptions.
NEUERO’s expertise in shipunloading solutions continues to play a key role in global grain logistics. The deployment of the M600 at Port Said is yet another testament to the company’s commitment to providing highperformance, sustainable unloading systems that meet the growing demands of modern bulk handling operations.
With its advanced automation, high efficiency, and focus on operational safety, the NEUERO M600 is set to make a lasting impact on Egypt’s grain import infrastructure, ensuring a reliable food supply for years to come.
Ongoing port terminal project at HES Gdynia Bulk Terminal in the Port of Gdynia.
pivotal: efficiency and capacity. With customized and flexible solutions, Cimbria supports their customers’ needs for reliability and high pace while increasing conveying and storage capacity including safe and gentle handling of crops to keep loss at a minimum. Cimbria is currently working on two large capacity grain port terminal projects in Poland.
Time is essential in the port terminal business. So, the more efficient the transportation of raw material such as grain, wheat, and barley can be, the better. As one of the strongest players in this field, Cimbria is proactively approaching customers regarding complete port terminal solutions, where both transportation and storage of grain and other crops are central elements in the customer requests. This happens at the same time as transportation routes for grain and seed are being restructured due to changes in the world markets with increasing demands from places like the Black Sea region, Egypt, the Middle East, Kazakhstan, and Brazil.
“We experience a global market pull for full scope supply of port terminal
wheat, and barley and high speed in loading and unloading as well as high storage capacity is an overall trend. Today we experience a high level of interest in heavy duty handling equipment with capacities of 1,000-1,500tph (tonnes per hour), which is almost the double of the average capacity request just a few years ago,” explains Thomas Mohr, General Manager in Cimbria, and continues, “Customers come to us because they prefer to deal with a one-stop-shop solution provider who can deliver turnkey projects on time. And with the most efficient and reliable storage and transportation solutions, we can secure that the raw materials keep their value and quality throughout the value chain.
One of the important and growing markets for Cimbria is Poland and currently Cimbria is working on two major port terminal projects there. One is for HES Gdynia Bulk Terminal in Port of Gdynia in the north-east of Poland. HES is expanding the current grain terminal intake capacity with 1,000tph and expanding with a new flat storage with a capacity of 64,000 tonnes. Furthermore, during the installation phase, this project was
expanded to include an additional silo
capacity of 20,000 tonnes. The Flat Storage project is currently in the commissioning phase and is expected to be taken into operation by the end of April this year, while the silos are currently being built and are expected to be completed by June.
“We delivered equipment for the bulk terminal in Gdynia in 2016 and we are happy to have a satisfied customer returning for an expansion of the facility. A part of the new project is a customized intake system with weighing bridges significantly speeding up the unloading process, including also our Moduflex dustfree Loading Chutes and an underground discharging system and movable and reversable conveyors ensuring a very flexible and adaptable solution. This ensures a larger capacity and a more efficient receiving and shipping of grain via Panamax ships. A flat storage facility is future-proofing the warehouse, so it can be used for both grain and soya meal storage,” says Mateusz Olejniczak, Manager Cluster Sales Lead in Cimbria Poland.
“The solution from Cimbria has been designed in close collaboration with us, and our long-term relation helped to deliver
the most effective solutions for our project. The new warehouse conveyors and handling equipment will contribute to a more efficient handling process. After completion, HES Gdynia will be able to offer higher level of quality, safety, and capabilities, providing much-needed space for such a supply constrained agricultural market, underpinning the terminal as the reliable logistic grain partner for our customers,” says Sonia Florczuk, Commercial Director at HES Gdynia Bulk Terminal.
Another Polish project is for Szczecin Bulk Terminal in Stettin in the western part of Poland. Similar to the development in Gdynia, this project is also an extension of an existing plant, that Cimbria has supplied handling equipment to in 2017. For the new project, Cimbria is delivering four silos with a total capacity of almost 28,000 tonnes and a ship loading line with an intake capacity of 1,000tph. This large project for Szczecin Bulk Terminal is currently under installation and is expected
to be completed by June/July this year.
“We are installing large amounts of extra storage capacity in a very narrow space, so we have put a lot of effort into the customization of the solution to match the specific needs and conditions. Furthermore, the silos are equipped with our intelligent temperature monitoring system that automatically manages and monitors grain temperatures 24/7 and warns in case of any hot spots. The system is an important part of maintaining high quality of the grain and preventing product loss and downtime”, says Mateusz Olejniczak.
“We are glad to be collaborating with Cimbria on this plant extension. Our fully automated silos and transshipment system allow us to offer both import and export handling to our customers, and with even more storage capacity we continue supporting the global food market by meeting the increased demand for secure and efficient storage and transportation of grain,” says Rafal Rozanski, Terminal
Manager at Szczecin Bulk Terminal.
Both port terminal projects in Gdynia and Stettin are ATEX certified. The Gdynia project is expected to be completed by Q4, 2024, and the project in Stettin will be finalized by 2024-2025.
“The Polish projects both matches very well our overall aim to support global food security and food supply with a growing world population to feed,” says Thomas Mohr.
Cimbria is a world leader in industrial processing, handling, and storage of cereals and seeds as well as animal feed, food, and other bulk products. Cimbria works closely with their customers to design, manufacture, install, and service customized solutions, individual machines, and complete turnkey systems. Cimbria is a brand within Grain & Protein Technologies business unit of American Industrial Partners, which includes Cimbria™, GSI™, Automated Production™ (AP), and Tecno™. The brands drive productivity for customers globally through smart and reliable grain and protein solutions to ensure food security, sustainability and animal welfare.
American Industrial Partners (“AIP”) is an industrials investor, with approximately $16 billion in assets under management. AIP is distinctively focused on industrial businesses across a broad range of end markets that include: aerospace and defense, automotive, building products, capital goods, chemicals, industrial services, industrial technology, logistics, metals & mining, and transportation, among others. AIP looks to generate differentiated returns by investing in quality industrial businesses with strong management teams and working with those teams to implement comprehensive operating agendas to build long-term value.
For over 20 years, Grain Capital — located in Odessa, Ukraine — has been a manufacturer of highly reliable and energyefficient grain handling equipment, offering comprehensive automation solutions for grain elevators and their business processes. One of the company’s key areas of expertise is the production of grain handling equipment, with the most indemand solutions being bucket elevators, chain conveyors, and sweep augers. In recent years, enclosed belt conveyors have been gaining popularity, gradually replacing traditional chain mechanisms.
KEY ADVANTAGES OF ENCLOSED BELT CONVEYORS
High throughput capacity of up to v 3,000 tonnes per hour: this makes them an ideal choice for port terminals, where cargo handling speed directly impacts financial efficiency.
Dust-free operation: the sealed v housing design minimizes dust emissions into the atmosphere,
enhancing environmental safety.
Conveying distance of up to 2,000m v per conveyor.
Suitable for outdoor operation v without the need for covered galleries. All bearing units are positioned v
outside the dust zone.
They are capable of handling materials v with temperatures up to 120°C.
Gentle grain handling: the belt v transport system significantly reduces grain breakage by 1.5–2 times, which is
crucial for grain processing enterprises.
Grain Capital’s grain handling equipment is widely used not only in the agro-industrial sector (grain elevators, flour mills, oil extraction plants), but also in food processing (sugar factories, flour production), construction (cement, sand), and chemical industries (mineral fertilizers).
For each industry, customized solutions are developed to accommodate the specific
requirements of material transport, including optimal material selection, conveying speed, and sealing levels.
For example, for an oil extraction plant, Grain Capital’s engineering team developed and manufactured horizontal inclined chain conveyors with different inclination angles. The design also accounted for the aggressive properties of meal, which contains residual solvents and is corrosive to metal.
Therefore, the equipment was made from corrosion-resistant materials, and the
vertical design allowed it to fit within limited space conditions.
During the handling of bulk materials such as grain, feed, flour, sand, ore, and fertilizers, significant amounts of airborne dust are generated. To minimize explosion risks, improve working conditions, and reduce environmental impact, Grain Capital recommends integrating dust aspiration systems at the design stage.
In some industries, collected dust needs to be returned to the production process. For this purpose, local filtration systems are installed at material transfer points, allowing dust recovery through selfcleaning filter regeneration systems.
Grain Capital’s solutions have received high recognition from major global players in the grain processing industry, including Bunge, ADM, Cargill, COFCO, and Louis Dreyfus Group. Grain Capital’s grain handling and dust control equipment is successfully operating at their facilities, meeting high European safety standards (CE, ATEX 21/22).
FROM FERTILIZER TO GRAIN: HOW AMECO ENHANCED A SHIPLOADER TO MEET EVOLVING MARKET DEMANDS
THE CHALLENGE
AMECO has a long history of supporting global trade in food commodities with its robust and reliable shiploaders. Since its inception in 1932, AMECO has been at the forefront of designing and manufacturing bulk-handling equipment, including shiploaders that handle everything from grains to sugar. Fast forward to today, and the company continues to play a vital role in the logistics of food commodities.
In recent years, a customer who had been utilizing AMECO’s shiploader for urea found itself needing to pivot to grain handling. The global upheaval caused by the Ukraine conflict had significantly impacted supply chains, forcing the customer to adapt quickly to changing market conditions. However, this shift presented several challenges, particularly in ensuring the efficient trimming and loading of grains onto Panamax-sized ships.
Despite its extensive experience, the customer encountered difficulties with grain trimming, leading to prolonged loading times. Its existing shiploader, originally designed for fertilizer, required enhancements to meet the new operational demands.
THE AMECO SOLUTION
AMECO’s team quickly engaged with the customer to understand its new require-
ments. Driven by a shared goal of optimizing grain loading efficiency, AMECO proposed a series of modifications to the existing shiploader.
HISTORICAL EXPERTISE MEETS MODERN NEEDS
Leveraging decades of experience in bulk handling, AMECO drew on its historical knowledge of grain logistics to propose
enhancements tailored to the customer’s specific needs. This involved increasing the speed of product flow by experimenting with the removal of some buckets and redesigning the output for better material distribution.
CUSTOM DESIGN ENHANCEMENTS
AMECO’s engineers suggested modifying
the machine’s output to introduce greater curving, allowing for a more precise and efficient grain-trimming process. Additionally, structural reinforcements were considered to handle the different physical properties of grains compared to urea, ensuring the shiploader’s durability and efficiency.
COLLABORATIVE APPROACH
Throughout the process, the customer’s curiosity and proactive engagement were key. AMECO provided continuous support, offering detailed consultations, conducting inspections, and proposing further redesigns as needed. This partnership ensured that the solution was not only effective but that it also aligned with the customer’s operational realities.
The customized modifications enabled the customer to seamlessly transition from handling urea to grains, significantly improving the efficiency of their grain loading operations. The enhanced grain trimming process reduced loading times and optimized the use of the shiploader, allowing the customer to better navigate the challenges posed by global supply chain disruptions.
Bruks Siwertell has received an order for a nextgeneration Siwertell 15 000 S road-mobile unloader from an undisclosed owner. The largest model Siwertell roadmobile ship unloading solution will offer environmentally friendly, efficient grain handling and comply with European Union (EU) directives for ATEXclassification, ensuring the safe handling of organic commodities.
“In mobile ship unloading terms, this is a significant contract, with a specialized configuration,” highlights Jörgen Ojeda, Sales Director, Mobile Unloaders, Bruks Siwertell. “The Siwertell 15 000 S road-mobile ship unloader is the largest mobile ship-unloading solution on the market today. This particular model also has ATEX-classified components and systems, enabling it to meet the highest safety standards for handling organic dry bulk materials, such as wheat and grain.
“Siwertell road-mobile unloaders have unrivalled performance capabilities,” continues Ojeda. “They not only offer high through-ship capacities, no spillage and dust-free unloading, but also handle sensitive organic materials, such as grain, very carefully. This means that all our screw-type Siwertell ship-unloaders minimize material degradation and preserve the quality of grain shipments.
“The good reputation of our road-mobile ship-unloading technology was fundamental in securing the order, along with the fact that we are the only manufacturer capable of delivering such a large, efficient mobile ship unloading system,” he adds.
Diesel-powered, next-generation Siwertell 15 000 S road-mobile unloaders feature Stage V/Tier 4F diesel engines, which comply with the latest EU emissions regulations, and are fitted with a double-bellows discharge arrangement and dust filters, ensuring efficient, environment-friendly material transfers.
Next-generation units also have advanced digital solutions and an integrated communications system that enables remote access, troubleshooting and support. This can be upgraded if, in the future, owners want to take advantage of Bruks Siwertell’s latest service support packages, which include the use of an augmented reality (AR)-kit.
The Siwertell 15 000 S road-mobile unit will offer a continuous rated wheat unloading capacity of 400 tonnes per hour, discharging vessels up to 15,000dwt. It will be delivered fully assembled towards the end of 2025.
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Concrete, install the sweep auger
Embedded angle Centre outlet
Wall plate
With the progress of science and technology and the development of industry, silos form an important part of modern logistics storage, write Wen Peng and Zhao Qiaoyi of Henan SRON Silo Engineering Co., Ltd. Technological innovation and performance enhancement of silos is always the focus of industry attention. Domestic flat-bottomed grain silo ventilation mainly relies on the floor
trough ventilation; these troughs are equipped with floor trough covers. The air from the centrifugal fan outside the silo enters the grain pile through the holes on the floor trough cover, and then spreads around the grain pile, achieving the purpose of cooling and dehumidifying the grain in the silo.
There are a number of drawbacks to traditional floor-trough ventilation, including the following:
Poor ventilation uniformity: the v floor trough ventilation is fixed and convenient, but there are ventilation dead corners, resulting in insufficient overall ventilation uniformity. This can affect the storage effect and quality of grain in the silo, such as grain temperature and humidity control. They can be difficult to clean and v maintain: the floor trough ventilation duct is located under the floor. If it is
not cleaned and maintained regularly, it will cause the ventilation duct to be blocked, affecting the ventilation effect. The total ventilation volume v limited by the cross-section and wind speed of the ground trough, and the ventilation time is long.
The fully ventilated bottom plate can solve the above problems well. The full bottom plate ventilation has a large ventilation area, can achieve uniform and efficient ventilation, and the ventilation time is short.
Henan SRON Silo Engineering Co., Ltd. uses a new type of groove cover plate which is made of galvanized sheet punching and then folding, with thin material, light weight, high strength. It uses less material than the traditional grain depot groove cover plate and saves costs.
Edge plate
Circumferential support
Fixed rivet
Angle steel for limit
Vent cover
Steel leg Supporting steel frame
The concrete foundation is built around the central discharge port of the fully ventilated bottom silo, and no ventilation trough is built in the rest of the area, so there is very little civil engineering.
The folded edge at the end of the floor trough cover not only improves the pressure-bearing strength of the single cover, but also solves the hidden danger of materials entering under the ventilation plate along the embedded angle steel.
SRON covers another piece of connecting plate on the two ventilated bottom plates side by side, and uses rivets to fix the connecting plate and the two sides of the ventilated cover plate to make it become one, so that not only there is no gap between the two monolithic cover plates, but also prevents the lateral movement between the ventilated cover plates (see Figure 4 on p128 for details).
SRON sets a circle of edge guard along the inner wall of the silo. The arc-shaped design and bridge-type punching are fixed to the ventilation bottom plate with rivets. The vertical surface of the edge guard is moulded according to the corrugation of the silo wall, and fixed with the silo wall by bolts. This solves the gap problem between the rectangular ventilation bottom plate and the circular silo wall.
In summary, the ventilation bottom plate of the solution to the low rate of
ventilation and cooling in flat-bottomed silos, the local existence of dead ends, suitable for the tropics, subtropics, suitable for ventilation timing is relatively small in
the vast area, to achieve in the limited natural conditions as soon as possible to complete the whole field silo ventilation and cooling needs.
NEUERO produces the most reliable and high-quality bulk ship loaders worldwide. Environmentally friendly with less dust, less noise and more efficiency | neuero.de/en
