Steffen Horchler, Regal Rexnord, highlights how integrated powertrain solutions and lifecycle support can improve performance, reduce downtime, and support long-term plant productivity.
Material handling equipment might not get the same attention as the kiln or the crusher, but it plays a critical role in the success of any cement plant. Chains, conveyors, and bucket elevators are the backbone of raw material transport, and when they fail, the consequences are immediate and costly.
Cement production is not a forgiving process. Between heat, dust, abrasion, and heavy loads, equipment is constantly pushed to its limits – and beyond. That is why plant teams are looking for more than just robust components; they want solutions that are built to last, supported by people who understand their reality.
A demanding environment
Cement plants have among the harshest working conditions found in any industry. The air is filled with fine, abrasive dust. Depending on the season, temperatures can swing from below freezing to well above 500°C near the kiln. Equipment has to operate outdoors, in high heat and humidity, through wind, rain, and sometimes snow.
In these conditions, chains in particular take a beating. They are used in virtually every bucket elevator, moving everything from raw feed to clinker and finished cement.
A failure here does not just mean a few minutes of downtime – it can bring production across the entire plant to a standstill. There have been instances where a single failed elevator caused more than a million dollars in lost output.
Of course, tough conditions are not impossible to overcome. It is just the challenges they present are not typically the kind that can be solved by generic components. Equipment intended for the cement sector needs to be engineered specifically for these demands, with features that simplify maintenance and extend working life.
Seeing the whole system
In complex, challenging operations like cement production, it is important not to look at individual components in isolation.
A worn chain might not be a sign of poor quality, but could just as easily be caused by misalignment, wrong positioning of the inlet chute, bearing wear, or excessive drive loads. That is why the most effective maintenance strategies view elevators and conveyors as full systems, not just collections of individual parts.
This systems-based approach involves considering how chains, sprockets, gear drives, bearings, shaft locking devices, and brakes interact under real-world operating conditions. When these components are chosen and designed to work smoothly with each other, the result is often a significant boost in both reliability and ease of maintenance.
For example, gear drives with horizontally split housings, like the Falk V-Class™, can make servicing quicker and less disruptive by allowing easier access to internal parts. Similarly, solid housing bearings with simplified installation and removal mechanisms can help reduce the time required during shutdowns. In high-dust, high-heat environments, electromechanical brakes that are sealed and self-adjusting – such as those found in Regal Rexnord's Stearns brand’s product line – can provide extra peace of mind for operators needing reliable load holding and minimal maintenance.
Chains designed for easier handling and inspection also offer benefits. Solutions like RexPro™ Engineered Steel Chain, for instance, aim to support safer, faster replacement during short maintenance windows, which is something many plants struggle with when operating under tight schedules.
The point is not to over-specify or overcomplicate systems, but to make smart choices that reflect the realities of the site and reduce complexity. By treating the system as a whole, plant operators can forecast chain end of life and plan for replacement, reducing the risk of unplanned failures and allowing for better long-term performance.
Support that lasts
Even the best-engineered systems need regular inspection and support, especially in industries like cement where equipment is constantly exposed to heat, dust, and abrasion. No component is truly ‘fit and forget’, and in many plants, maintenance teams are responsible for hundreds of assets, often across multiple disciplines.
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