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Speeding up wagon unloading

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Today a majority of one million tonne integrated cement plants have wagon unloading system. It has become a necessity considering the quantum of materials handled at a regular frequency. It is commonly known as wagon tippler.

The material can be received at a plant by two different types of wagons – BOXN wagons and BOBRN wagons. Generally the material will be discharged from the top in BOXN wagons, while in the case of BOBRN wagons, it will be discharged from the bottom.

The hopper will be provided below the ground for receiving the unloaded material from these wagons.

Hence, BOXN wagons need to be tilted for unloading the material into the hopper, while the BOBRN wagons are provided with pneumatically operated gates at the bottom for unloading the material. A majority of our plants have been using BOXN wagons. In most of the cement plants, coal is received and handled through wagon tippler system.

Wagon tippling system
The wagon tippling system consists of a wagon tippler, the wagon positioning equipment, underground hopper, and feeder below the hopper for evacuating the material unloaded into the hopper. The wagon tippler consists of a table for positioning the wagon, wagon holding mechanism, gears and pinions for rotation, drive unit, hydraulic power pack, etc.

The unloading cycle starts when the wagon is positioned over the wagon tippler table and the wagon along with the table rotates and discharges the material into the underground hopper. The time taken for the unloading operation is about 90 seconds. There are two types of wagon tipplers: rota side that rotates about 135-degree, and another rotary type that rotates 180 degree. The rota side wagon tipplers are provided in most of the plants in India. The drive for the rotation will be hydraulic type for smoother operation with the rota side wagon tippler.

Most of the suppliers of the system are claiming 24 tips per hour with the rota side on tippler. However in reality, the plants are getting maximum 18-20 tips per hour. However there is an improvement in the total load handled per tip which has gone to 150 tonne from 110 tonne. In all the entire railway reck is unloaded in about four hours’ time.

Wagon positioning equipment
There are different types of wagon positioning equipment like hydraulically operated side arm charger, beetle charger and shunting locos. The hydraulically operated side arm chargers are being used in most of the plants in India as this equipment is much faster compared to the others. The tractive force of the side arm charger shall be suitable for hauling one fully loaded rake.

Unloading hopper
The hopper provided below the wagon tippler could be either reinforced cement concrete (RCC) type or structural steel fabricated type. In most of the plants, this will be of RCC construction. Suitable liner would be provided for this hopper depending on the abrasiveness of the material handled. Generally steel grids of 250 mm square will be provided above the hopper to avoid higher size of material going through. The higher size material will be removed and broken separately and then passed through the grid. The grid will be sloping outwards for easy removal of such larger size material.

Feeder blow the hopper
The feeder below the hopper could be either vibrating type feeder or apron feeder. The apron feeder would be more suitable for heavy duty application for taking the impact of the falling material. The apron feeder will be driven by hydraulic motor for smoother operation.

Dust control system
Plain water spray type dust suppression system will be provided for suppressing the dust generated during the unloading operation. Spray nozzles will be provided at the top of the wagon tippler and also around the hopper for spraying the water and settling the dust. An enclosed shed will be provided for the wagon tippler so that the dust will be contained within and will not be spread to the other parts of the plant.

Control room
A control room will be provided adjacent to the wagon tippler at an elevated position for operation and control of the wagon tippling system. The complete view of the unloading system will be available from this control room. Generally the time taken for unloading the rake would be about 4 hours with one wagon tippler in operation.

Unloading system track hopper: (BOBRN wagons)
The BOBRN wagons will be discharging the material through the discharge gates provided at the bottom of the wagons. This type of unloading system consists of track hopper below the rail track, mechanism for opening the pneumatic gates of the wagons and feeders below the track hopper. The loaded rake will be brought to the track hopper by the main line locomotive and the same locomotive will stay connected to the rake while the unloading operation is in process and the rake will be hauled out of the plant. It is not necessary to disconnect the loco from the rake unlike in the case of wagon tippler system.

Track Hopper: (BOBRN wagons)
The track hopper will be provided below the rail track and will be suitable for holding the material unloaded from the BOBRN wagons. The length of the track hopper adopted in most of the Indian plants is about 200 m and the capacity of this hopper will be suitable for storing one rake material. With this, it would be possible to operate the wagon unloading system independent of the rest of the plant and the rake need not wait in case any of the downstream equipment is not available. There are a few plants with shorter length of track hopper. It would be possible to adopt track hopper of reduced length as the reliability of the conveying equipment is higher. The track hopper will be of RCC construction and suitable liner will be provided depending on the abrasiveness of the material. Steel grid of about 250 mm square will be provided over the track hopper.

Discharge gate opening mechanism: (BOBRN wagons)
The BOBRN wagons have pneumatically operated gates at the bottom of the wagon. These need to be opened for discharging the material from the wagons. The wagons will have hopper like construction with slope at the bottom portion for effective clearance of the material. The pneumatic gates could be opened by energising the solenoids provided on the wagons. The gates could be closed by de-energizing the solenoids. The opening and closing of the gates could be carried out either manually or with the help of line-side equipment. In case of manual operation, about 15 to 20 wagons will be parked on the track hopper for unloading the material. Once this batch of wagons is unloaded, the next batch of wagons will be pushed forward and parked on the track hopper for unloading operation. This process will be repeated till the completion of unloading operation. In case of line-side equipment, the unloading operation could be done while the rake is in motion.

The compressors required for supplying the compressed air could be either mounted on the locomotive used for hauling the rake or could be in a separate room near the track hopper.

Feeder below the track hopper: (BOBRN wagons)
The paddle feeders will be provided below the track hopper for evacuating the material from the hopper. The paddle feeder will be mounted on the table provided below the hopper from where material will be evacuated and fed on the belt conveyor below.

Rail tracks
The layout of the rail tracks shall be such that the track will be straight and horizontal for one rake length on the inhaul side and also on the outhaul side. In case it is not possible to have straight length to accommodate one full rake on either side, at least about 250 m on either sides of the track shall be made straight and the balance could be on a smooth curve. It would be preferable to provide Merry Go Round (MGR) system of rail track so that the rake can enter the plant in one direction and go out of the plant without any need of disconnecting the loco from the rake. The Dust Control system and facilities like Central Control system will be same described earlier.

Article by H Ramakrishna of Tata Consulting Engineers Ltd, Bengaluru.

Economy & Market

Power Build’s Core Gear Series

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

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Economy & Market

Conveyor belts are a vital link in the supply chain

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

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Economy & Market

Impactful Branding

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Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.

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