Simmy Maan, Proprietor, Constromech Engineering Solution, gives insights into customised solutions that are AI-driven, ensuring smoother operations, reduced downtime and a greener, safer working environment.

In this interview, Simmy Maan, Proprietor, Constromech Engineering Solution, shares insights on how advanced design and technology are revolutionising bulk material handling in cement plants. From minimising spillage and dust to optimising energy use and throughput, he highlights practical solutions and next-generation innovations that enhance efficiency, sustainability and operational reliability.

How do you design bucket-elevators and belt conveyors to minimise spillage and dust in cement plants?
At Constromech, we build in extra safeguards beyond standard practice: fully sealed loading / unloading chutes, deflector liners, anti-spill lips, segmented dust curtains and primary / secondary air extraction ports. For instance, in a cement line upgrade, we retrofitted transfer zones with diving chutes and side sealing plates, reducing carry back by approximately 25 per cent. We also use high-precision alignment of head and tail shafts, skirting with tensioned rubber seals, and incorporate self-cleaning belt scrapers (primary/secondary) as per good belt conveyor design guidelines. In high-dust zones, we provide vented or negative-pressure enclosures.

What advantages do plate-link / round-link chain elevators offer vs traditional systems for heavy raw materials?
Plate-link and round-link chain elevators provide high durability, temperature tolerance, minimal elongation and resistance to abrasive material impact. In our practice, we often combine these with belt-bucket elevators in projects where gentler handling of materials is required (e.g., additives or blended raw mix). The belt-bucket hybrid allows quieter operation, lower noise, and reduced wear on chains when loads are moderate, while chain types are used for aggressive duty. In one cement plant, we substituted a conventional bucket elevator with a belt-bucket design for handling hydrated lime. The result: lower vibration, less maintenance and longer chain life.

How do apron feeders or drag chain conveyors help in ensuring steady material feed without overloading?
Apron feeders give a metered, consistent flow using rigid pans and heavy drive chains. We are currently developing and soon introducing our belt-apron feeder variants that combine belt flexibility and pan-type strength. For drag conveyors, we have both forged chain and fabricated chain versions, available in single or double strand and with various attachments (flights, paddles, blades). Selection is based on material density, load profile and abrasiveness. In one case, for raw mix at 2,500 kg/m³, we used double strand forged drag chain with paddles and achieved stable feed to the kiln without surges.

What challenges do you face when scaling material-handling equipment for the high throughput needed in large cement plants?
When scaling conveyors, feeders or elevators for 500+ tph regimes, structural rigidity, vibration, drive sizing and thermal expansion become significant design challenges. We address this by using finite element stress analysis, oversizing bearings, modular supports, and pre-engineered expansion joints. We also routinely carry out retrofit jobs — e.g. converting chain elevators to belt-bucket systems or vice versa, enhancing capacity, changing inclination angles, or upgrading cross-sections. In one plant, we converted a chain elevator of 600 tph to a belt-bucket modular model, improving uptime and reducing wear.

How important is maintenance and spare parts availability for flow conveyors and reclaimer systems in reducing downtime?
Downtime in flow conveyors or reclaimers directly impacts production continuity. At CMECH, we supply ready-made spares in standard sizes — sprockets, rollers, rim segments, chain pins and bushes (for specific designs) — which our agents or clients can stock locally. We design equipment with easy access panels and quick-release modules, so replacement takes minimal time.

With increasing focus on sustainability,how do you optimise power consumption in equipment like deep pan conveyors and elevators?
We embed energy-efficiency in mechanical design: optimising pan or bucket pitch to minimise drag, using low-friction chain and liners, selecting high-efficiency gearboxes, and sizing drives with a proper safety margin (not oversizing excessively). In one 1,500 tph deep-pan conveyor, we reduced drive power by approximately 7 per cent by optimising pan depth and chain clearances. Additionally, we offer laser and IR guided monitoring modules, which operate without reliance on internet or mobile coverage and transmit data directly to mobile phones with graphical reports and AI-driven diagnostics. These modules can measure physical, chemical, or kinetic parameters (e.g. temperature, vibration, load trends) on conveyor belts, kilns, coolers, crushers, ball mills, VRMs, roller presses and packing lines. This real-time data allows operators to fine-tune speed settings, reduce idling, and detect inefficient consumption early — promoting sustainable operation.

How does Constromech customise bulk handling solutions to the different raw / processed material densities (limestone, clinker, additives)?
We begin by characterising bulk density, moisture content, abrasiveness and flow characteristics. Based on that, we size bucket volumes, chain pitch, belt width, conveyor inclination, and liner materials. For example, for clinker (~2,900 kg/m³) we may use shorter bucket spacing, heat-resistant liners, and forged chains; for lighter additives (1,200–1,500 kg/m³) we may use belt-bucket systems or gentler chain pitch. In one project, we provided hybrid conveyors in a plant handling both raw mix and gypsum, tailoring each section’s geometry to its specific material behaviour.

What innovations or design improvements do you believe will define the next generation of material handling in the cement sector?
Looking ahead, modular plug and play conveyor units, adaptive control via AI, self-aligning mechanisms, self-lubricating chains and IoT-integrated monitoring will set new benchmarks. Our integrated laser/IR modules with local-edge AI will be a part of that evolution. Use of predictive maintenance algorithms (deep reinforcement learning) will determine the optimal inspection intervals and minimise unplanned stoppages at the specific plant levels. Enclosed conveyors with active dust suppression, use of eco hoppers, dynamic flow control and modular upgradeability will also shape the next generation of material-handling systems in the cement sector.