Case Study: How WNC Helped an Ohio Aggregate Yard Cut Railcar Unloading Times in Half

One of our aggregate industry customers contacted us because they were hoping to improve unloading times at one of their Ohio aggregate yards. The yard was experiencing material flow issues during the unloading of crushed stone, sand and gravel from hopper railcars. This was leading to prolonged unloading times, and high carryback. Their existing process was leading workers to manually strike railcar sides with sledgehammers to dislodge stuck material and restore flow. Their current process was causing them:

Prolonged Unloading Times

Prolonged unloading times were leading to a reduction in the productivity of the yard. As the first step in the preparation of the material for load out at the yard, a delay in unloading cascade throughout the entire yard.

Carryback

Carryback, or the residual material that remains in the railcar after unloading, is a cost to the yard. They pay for the materials based on the railcar’s weight at loading and any material not unloaded is paid for but never received. This increases the cost of the material and can add up when unloading thousands of railcars a month.

Worker Safety Concerns

Swinging sledge hammers to dislodge the stuck material was a safety concern as well. Picking up and swinging sledge hammers on a repeated basis is not ideal and increases the potential for injury.

Wm. Neundorfer & Co’s Solution Development Process

For this project, Wm. Neundorfer & Co. worked with the customer to gain a full understanding of the issues the customer was facing and their requirements for a solution.

Based on the information provided, Wm Neundorfer & Co determined that the NAVCO Railside Railcar Shaker would be the optimal solution. Our partners at NAVCO have provided bulk material flow solutions for generations and have a complete range of products designed specifically for hopper railcars. A major deciding factor on the correct equipment to supply was the yard’s railcars did not always have dovetail brackets on their hoppers. This limitation eliminated the NAVCO HCP Railcar Vibrator from being a possible solution. The Railside Railcar shaker was chosen based on the equipment’s proven performance in similar aggregate handling environments and its compatibility with the facilities existing infrastructure.

The Technical Solution: NAVCO Railside Railcar Shaker

We recommended the NAVCO Railside Railcar Shaker, which represents advanced vibratory technology specifically engineered for bulk material unloading in hopper railcar applications.

How the Railside Railcar Shaker Works:
The system operates through a precise sequence: after railcar discharge gates are opened, pneumatic cylinders deploy to extend a specialized contact beam lined with ultra-high molecular weight (UHMW) polyethylene against the railcar’s sidewall. Upon secure contact, the unit’s integrated vibratory “unbalanced” motors activate, transmitting controlled vibration through the railcar structure.

This mechanical vibration effectively breaks up material bridging and promotes consistent flow, enabling rapid and thorough railcar discharge while minimizing residual material and reducing manual intervention requirements.

The customer was interested in the solution suggested, but wanted to test the equipment in their application before they decided to purchase.

How the Railside Railcar Shaker Works:

The system operates through a precise sequence: after railcar discharge gates are opened, pneumatic cylinders deploy to extend a specialized contact beam lined with ultra-high molecular weight (UHMW) polyethylene against the railcar’s sidewall. Upon secure contact, the unit’s integrated vibratory “unbalanced” motors activate, transmitting controlled vibration through the railcar structure.

This mechanical vibration effectively breaks up material bridging and promotes consistent flow, enabling rapid and thorough railcar discharge while minimizing residual material and reducing manual intervention requirements.

The customer was interested in the solution suggested, but wanted to test the equipment in their application before they decided to purchase.

Equipment Trial

Our partners at NAVCO offer a trial service for the Railside Railcar Shaker for occasions just like this. We worked with the customer and NAVCO to setup the delivery and install of a trail shaker for the customer to test the equipment at their yard for twelve business days. Before the shaker could be shipped out, we worked with the customer to ensure that the yard was able to meet the utility requirements (air supply, electricity, etc.) and had an installation pad capable of supporting the shaker during operation. The customer already met most of the requirements and only had to run a temporary 480V power supply for the trial.

Once the utility requirements and pad details were worked out the customer picked a date for when they would have a good number of railcars at their yard to unload and run the trial. We worked with NAVCO to have the shaker delivered on the agreed upon date. Representatives from both Wm. Neundorfer & Co. and NAVCO were on location to supervise the commissioning of the shaker. Once the shaker was installed the unloading of the railcars began. We provided guidance on how to operate the shaker at different setting that could be adjusted to help find the optimal means to unload the material.

From here the customer took over and worked through unloading hopper railcars. The customer tracked the unloading times of the different materials (crushed stone, sand and gravel) and at the end of the trial compiled a report on their findings.

Once the utility requirements and pad details were worked out the customer picked a date for when they would have a good number of railcars at their yard to unload and run the trial. We worked with NAVCO to have the shaker delivered on the agreed upon date. Representatives from both Wm. Neundorfer & Co. and NAVCO were on location to supervise the commissioning of the shaker. Once the shaker was installed the unloading of the railcars began. We provided guidance on how to operate the shaker at different setting that could be adjusted to help find the optimal means to unload the material.

From here the customer took over and worked through unloading hopper railcars. The customer tracked the unloading times of the different materials (crushed stone, sand and gravel) and at the end of the trial compiled a report on their findings.

Once the utility requirements and pad details were worked out the customer picked a date for when they would have a good number of railcars at their yard to unload and run the trial. We worked with NAVCO to have the shaker delivered on the agreed upon date. Representatives from both Wm. Neundorfer & Co. and NAVCO were on location to supervise the commissioning of the shaker. Once the shaker was installed the unloading of the railcars began. We provided guidance on how to operate the shaker at different setting that could be adjusted to help find the optimal means to unload the material.

From here the customer took over and worked through unloading hopper railcars. The customer tracked the unloading times of the different materials (crushed stone, sand and gravel) and at the end of the trial compiled a report on their findings.

Results of the Trial

Based on the customer’s findings they saw a reduction in unloading times of 40%–50% when unloading 100 railcars compared to the manual methods they had been using. In addition to the reduction in unloading times the customer noted they were receiving more material. They attributed this to the capture of material they were previously losing to carryback from never getting it out of the railcar. It was also noted that sledge hammers were not needed at all during the trial.  The customer was excited to see this big of a reduction in unloading times, increase in and a purchase order was placed for a Railside Railcar Shaker within a week of the trial concluding.

Results Confirmed in Permanent Installation

With the purchase order submitted, Wm. Neudorfer & Co. worked with NAVCO to coordinate the manufacture and delivery of the new Railside Railcar Shaker to the customer. Following successful permanent installation and commissioning, the customer confirmed the improvements in railcar unloading efficiency that were demonstrated during the trial.

Time Savings:

Average unloading time for 100-car shipments reduced by approximately 40% – 50% – matching the results achieved during the trial.

Safety Enhancement:

Complete elimination of manual sledgehammer interventions, permanently improving workplace safety.

Carryback Recovery:

The average material received per railcar maintained its increase over unloading without the shaker.

Ongoing Benefits:

Continued productivity improvements. Production delays due to slow or stopped railcar unloading are no longer an issue.

The conversion from manual intervention methods to automated vibratory assistance significantly improved our client’s operations, enabling higher throughput with improved worker safety. The testing phase proved invaluable in demonstrating real-world benefits and ensuring our customer’s confidence in the solution.

Ready to Optimize Your Railcar Unloading Operations?

Wm. Neundorfer & Co. is Ready to Help

If your aggregate operation is facing similar railcar unloading challenges, we’re here to help. Contact Wm. Neundorfer & Co. today to discuss how we can work together to identify and implement the right material handling solution for your specific needs.

Contact us to schedule a site assessment and explore how NAVCO’s vibratory equipment solutions can transform your operations.