Profits Through Savings: How Equipment Standardization Saves Operating Costs and Improves Revenue

Material handling efficiency is the name of the game when it comes to cement plants’ profitability – which means it should be among the top priorities of the operation.

Multiple types of bulk raw or refined material must consistently move through the cement-making process, so conveyor performance is a chief concern. Any mechanical or electrical issues that occur lead to costly downtime, lost revenue and even risks of safety or environmental penalties.

The good news is that the opposite is also true. The right conveying systems help you avoid problems and improve production efficiency – as long as three things happen with the equipment:

1. It is properly spec’d, built and installed
2. It conveys the material it was designed for
3. It is properly maintained

This is especially important for conveyors in cement operations because of the varying characteristics, temperatures and volumes with materials including clay, limestone, gypsum, sandstone and clinker.

With so many variables, expensive problems are sure to arise if left unchecked. So, how can plants be strategic about minimizing – or avoiding – unplanned downtime before it happens?

Standardizing Cement Plant Equipment Cuts Expenses and Improves Production

Traditional MRO (maintenance, repair and operations) procedures for cement plants are becoming increasingly ineffective for facilities that utilize mismatched or misapplied equipment.

For example, plants operating with piecemealed or outdated conveyors are asking for trouble. If technical issues occur, they are difficult to address if the right parts or qualified repair personnel aren’t on-site, and an even bigger challenge if no standard equipment or maintenance strategy is in place. When you factor in the remote location of many plants, a lengthy, expensive downtime is usually the result.

But there are ways to maintain the conveyors’ reliable performance while reducing expenses for a healthier bottom line.

Standardizing equipment in the plant not only simplifies the operation, including maintenance, but it improves performance and output as well. This starts with having the right conveyors for the material, and then shifting the mindset from maintenance being part of reactive quality control to a process that can help turn profits.

Consolidating Equipment Suppliers Eases the Strain on Plant Personnel, Too

Standardized conveyors are much easier for plant managers and maintenance teams because maintaining products from a single manufacturer creates stability and eliminates guesswork. Working with one source, plant personnel can focus more on other processes without juggling multiple vendors for service and parts.

Furthermore, working with one reliable vendor can address several potential problems long before they occur.

A reputable manufacturer will always build the conveyors for a specific material or stage of the cement-making process, which enables consistent performance and simplifies maintenance tasks for the on-site staff.

Cement operations will also realize cost reduction benefits through equipment standardization such as energy savings, reduced waste and improvements in operational efficiency. The result is a more streamlined process that improves profitability.

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This article is part three of our three-part series, “Modernizing the Cement Plant.” Continue reading here:

• Part one
• Part two
• Part three

Learn more about the CDM manufacturing process here.
Visit this page for CDM’s conveying systems brochure, including tech specs and material and design information.

About CDM

The CDM story is about understanding that every industrial operation is different — as are their conveying challenges. A custom-engineered conveying system is a cost-effective approach to any operation willing to have a partner who is vested in your success and one who stands by their product.

CDM has earned more than 91 percent repeat business because we’re more than just a conveying systems manufacturer — we’re a business partner.

For additional information contact:

Andrew Parker, President CDM Systems, Inc.

Andrew@cdmsys.com  • cdmsys.com