Breaking Barriers in Bologna

In the world of cement imports, efficiency and flexibility are crucial. Cement producers continually analyse market trends, allocating their exporting capacities to different regions based on expected consumption. However, sudden spikes in demand or shifts in economic conditions require quick strategic changes and rapid adaptation to maintain or gain market leadership.

In recent years, Italy has experienced an increase in cement imports, despite a slight contraction in domestic consumption. This shift has created a complex market environment, where efficiency in logistics and cost-effective packaging solutions play a crucial role. In response, big bags (FIBCs) have emerged as a game-changer, facilitating the handling and transportation of imported cement while offering a practical alternative to traditional bulk terminals.

The challenge of bulk cement terminals

One of the biggest obstacles in setting up a bulk cement import terminal is securing a suitable location and obtaining the necessary approvals. While ports are the natural entry points for bulk shipments, they come with strict zoning laws, environmental concerns, and high infrastructure costs. Securing permits for bulk terminals can take years, with community opposition and bureaucratic hurdles often delaying projects indefinitely.

Big bags, on the other hand, eliminate the need for dedicated bulk terminals. They enable cement to be stored and distributed from inland locations, such as industrial zones and logistics hubs, where planning approvals are far easier to obtain. A basic warehouse equipped with forklifts and bag-cutting stations is often sufficient, making this approach faster, more cost-effective, and far more flexible than traditional bulk handling.

Recognising these advantages, Royal Cement Italia Srl decided in 2021 to establish a big bag import facility in Bologna, strategically positioned to serve the heart of Italy’s construction industry.

The technical solution: a lean and efficient setup

The chosen facility design prioritises efficiency and simplicity, comprising three core components:

• A debagging station for unloading big bags and transferring cement into silos.
• A storage unit capable of holding up to 500 t of white cement.
• A bulk loading station for road tanker distribution.

Debagging station: ensuring a clean and efficient process

The indoor debagging station consists of a twin hopper system, where big bags are delivered via forklift. This setup allows operators to position a second big bag while the first is being emptied, significantly enhancing productivity. For further optimisation, overhead cranes can be added, allowing multiple bags to be handled simultaneously.

A crucial component of this station is its dedusting unit, which ensures that no cement dust escapes into the warehouse, maintaining compliance with health, safety, and environmental (HSE) regulations. Once emptied, the cement is transported via screw conveyors to a vibrating screen, which ensures product quality by filtering out contaminants and preventing waste.

Following the screening process, an additional screw conveyor transfers the cement outdoors to a bucket elevator feeding system. This system is capable of handling up to 55 tph, ensuring a smooth and controlled flow while preventing contamination from moisture or environmental exposure.

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Read the article online at: https://www.worldcement.com/special-reports/07052025/breaking-barriers-in-bologna/