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Raw material stacking and reclaiming

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R Murthy and Santhosh Kumar M elaborate on the use of stackers and reclaimers used in cement industry for feeding raw materials.
Stacking raw materials/fuels and reclaiming them is an essential part of cement industry. Stacking of raw material is done in order to have sufficient raw material to feed the plant during any unforeseen supply stoppage. Also, stacking and reclaiming is done in specific pattern to blend the material and ensure uniformity in material for stable process.

Quarry management is an art: most quarries will probably have?good quality lime stone?from which cement can easily be made. Cement producer may also have some material that is not good enough. This might be harder to grind, or be of less suitable chemical composition.

If the ?good stuff? is all used up first, it may be more difficult to make cement out of what is left. Careful selection on a day-to-day basis is needed to make the optimum use of all the raw materials available.

The process
Raw materials are extracted from the quarry, crushed, stored by stacking and reclaimed in specific pattern to achieve pre-blending. The crushed material is ground with other additives as necessary to provide a final recipe for final blending. The pre-blended raw material/meal is stored in a continuous storage-cum-blending silo before being fed into the kiln. The silo stores several days? supply of material to provide a buffer against any glitches in the supply of raw material from the quarry.

Technically, a cement producer can have almost complete control over clinker composition by pre-blending raw materials of different compositions to produce the desired result. In practice, however, clinker composition is largely determined by the compositions of the locally available raw materials, mainly lime stone which makes up bulk of the raw meal.

Supplementary materials are used to adjust the composition of the raw meal, but cost and availability are likely to determine the extent to which they are used. Transport costs in particular becomes significant in view of the large quantities of materials (limestone) used in making cement.

Promac Engineering Industries Ltd has supplied many linear stackers, bridge-type reclaimers and side scraper reclaimers.

Linear stacker
This machine (Pictu re-1) basically has a travelling tripper and a luffable boom conveyor. The crushed material of suitable size carried from quarry is elevated and dropped onto the boom conveyor through the travelling tripper; in turn the boom conveyor drops the material on the yard. The boom conveyor can be luffed to required height, either by winch rope or by hydraulic cylinder.

Promac has supplied a number of linear stackers for various cement plants in India and abroad, like, JK Cement Fujairah (UAE); Lake Cement Ltd, Tanzania; Sagar Cements (formerly known as BMM Cement); India Cement etc; all working satisfactorily. The capacity of stackers vary from 300 TPH to 800 TPH.

In order to blend the raw material stored, it is necessary to stack the material in a specific pattern. Stacking pattern has to be decided based on the type of reclaimer we intend to use. If we use the bridge-type reclaimer, the pattern of stacking is multilayer stacking, as shown in Figure 1. More the number of layers, better the blending efficiency.

In this type of stacking method, the material is stacked layer over the layer to make a heap of required height and length to have the desired storage capacity. Here, it is ensured that different quality material is stacked in multilayers. When the Harrow of Bridge type reclaimer (pictu re-2) travels across the width of the stock pile, it grabs all the layers and feeds almost uniform mixture of raw material to the buckets of the bridge reclaimer. To achieve better homogenisation of the mixture of raw material, it is essential to know the different qualities of materials the mines is going to send to the stock yard during a particular period and to have as many ?layers? as possible.

Promac has supplied a number of bridge-type reclaimers till now for various cement plants in India and abroad: JK Cement, Fujairah, UAE; Lake Cement Ltd., Tanzania; Falcon Cement, Bahrain; BMM Cement; India Cement; etc., all working satisfactorily. The capacity of reclaimers vary from 150 TPH to 600 TPH.

Side scraper reclaimer
In the case of side scraper reclaimer (Pict ure-3), stacking to be done in ?mult i heap stacking? (figure 2) method. This means different quality materials have to be stacked in a heap one beside the other. So, when the side scraper grabs the material, almost constant portion of all different quality materials will be transported, forming a homogenised mixture.

Promac has supplied a number of side scraper reclaimers till now for various cement plants abroad to JK Cement, UAE and Lake Cement, Tanzania, all working satisfactorily. The capacities of reclaimers are 300 TPH to 170 TPH correspondingly.

Stacker-cum-reclaimer/Bucket wheel reclaimer
In the event, if there is no need of homogenisation and to handle considerably big volume of material, the option is to go for bucket wheel stacker-cum-reclaimer. A single machine can stack the material and can reclaim from the stockpile with the help of a bucket wheel provided at the end of the boom conveyor. Unlike linear stacker, in which the boom does not swivel around the centre point, here the boom conveyor along with the bucket swivels around the centre point. With this, one can get pyramidal frustum shape. This increases the stacking capacity for the same boom length and also, swivel enables the bucket to reach all points of the stock pile to reclaim the material.

There are two types of stacker-cum-reclaimers, namely, uni-directional stacker-cum-reclaimer and reversible stacker-cum-reclaimer. In the case of uni-directional stac ker-cum-reclaimer, the material is transported in one direction by the yard conveyor. This means, the material is fed at the tail-end of the yard conveyor and after stacking and reclaiming, it is delivered to the head-end of the yard conveyor. Whereas in reversible stac ker-cum-reclaimer, the yard conveyor is reversible in design. Therefore while stacking, the material is fed to the yard conveyor in one direction and after reclaiming, returns from the yard conveyor in the reverse direction.

Promac has supplied stacker-cum-reclaimers to the power industry and these machines are working satisfa-?ctorily in two different coal-based thermal power plants for eight years.

The authors are associated with Promac Engineering Industries Ltd, Bengaluru.

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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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