Industrial Solutions for the Cement Industry

In a cement facility, the conveyor system is the most critical link. Conveyor systems in these facilities must be designed for the weight and abrasiveness of limestone, clinker, and finished cement. Through our partnership with Conveyors Etc., we provide engineered-to-order transport solutions:

• Heavy-Duty Belt Conveyors: Designed for high-tonnage transport of both raw and processed materials.
• Vertical Transport: Custom bucket elevators and steep-angle conveyors for moving material into silos and kilns where space is limited.
• Turn-Key Systems: From initial conceptual design and engineering studies to the final installation and commissioning, Wm. Neundorfer & Co. and Conveyors Etc. provide a one stop shop for your material handling infrastructure.

Whether managing raw meal or finished Portland cement, accurate inventory data is critical for supply chain management. Cement silos present unique challenges: thick dust, high temperatures, and uneven material surfaces.

To address these challenges Wm. Neundorfer & Co. partners with BinMaster, a premier manufacturer of level sensors and inventory management solutions, to provide:

• Continuous Level Monitoring: We utilize BinMaster NCR-86 Radar and 3D Level Scanners to provide precise volume data, through the thick dust found in cement silos.
• Point Level Safety: Reliable rotary and vibrating rod sensors act as vital fail-safes to prevent overfills and dry-runs.
• Cloud Access: With BinCloud® and CementView®, terminal managers can monitor inventory across multiple regional locations in real-time via a smartphone, tablet, or PC.

Cement facilities often encounter material flow blockages due to material characteristics and environmental factors that slow and even halt production. NAVCO’s vibratory equipment and industrial vibrators are engineered to keep bulk materials flowing and production moving.

• Distribution Terminals: NAVCO railcar shakers and truck vibrators accelerate the unloading process while also reducing costly carryback.
• Flow Aids: Specialized bin and pipe vibrators eliminate material bridging and ratholing that can bring production to a halt.

In cement production, everything downstream depends on consistent, reliable material flow. When feeders struggle with abrasive raw materials or fine powders, the impact shows up in throughput, quality, and downtime. Through our partnership with JVI Vibratory Equipment, Wm. Neundorfer & Co. provides feeding and screening solutions built for the harsh realities of cement processing:

• Electromagnetic Pan Feeders: Infinitely adjustable to match process demands, delivering repeatable material flow for consistent production.
• Enclosed Tube Feeders: Move fine cement powder while containing dust and minimizing environmental exposure.
• Classifying Screens: Ensure material consistency before it reaches the mixer, reducing off-spec batches and wasted energy.

Cement Kiln Dust (CKD) presents significant handling and environmental challenges. To address this, Wm. Neundorfer & Co. partners with DustMASTER to provide advanced mixing systems that transform a difficult byproduct into a resource.

• Dust Processing & Conditioning: DustMASTER systems allow for the safe, dust-free processing of kiln dust. By precisely adding moisture, these systems convert a volatile waste product into a manageable, recyclable, or easily transportable material.
• Sustainability & Safety: Beyond simple disposal, these systems help plants meet environmental regulations while protecting workers from the respiratory hazards of dry CKD.

As stated above, the conveyor system is critical to a facilities infrastructure. Knowing how much material is moving on the conveyors and that the conveyors are operating correctly ensures that the facility is able to maximize production. Through our partnership with BulkPro Systems, we provide industry-leading dynamic weighing systems, conveyor safety equipment, and monitoring accessories:

• Belt Scale Systems: High-accuracy weighing system that provide real-time data on flow rates and totalized tonnage of bulk material moving through the facility.
• Safety Switches: Pull-cord switches and speed sensors for immediate emergency stops and slip detection.
• Misalignment Detectors: Preventing costly belt damage and material spillage by ensuring the belt stays on track.

Cement manufacturing is one of the most punishing industrial environments. We provide specialized protection to extend the life of your facility:

• Refractories & Coatings: Sauereisen provides high-temperature refractories for kilns and polymer concretes for areas exposed to chemical attack.
• Magnetic Separation: In-line magnets and overhead separators remove tramp metal from raw material streams, protecting expensive crushers and grinders from damage.

Abrasive materials like raw meal, clinker, and fly ash wear through standard valves and pipe bends quickly, leading to frequent replacements and unplanned downtime. Through our partnership with Bush & Wilton, Wm. Neundorfer & Co. provides heavy-duty flow control valves and wear-resistant conveying components engineered for the most demanding pneumatic conveying applications in cement production:

• Tapered Bore Rotary Airlocks: Adjustable rotor clearance compensates for wear in place — no disassembly required. Provides a reliable pressure seal to prevent blow-back while metering dry bulk materials.
• Slide Gate Valves: Six series available, from manual gravity models to pneumatically operated, dust-tight configurations for pressurized systems.
• Conveying Diverter Valves: Compact, leak-proof designs with positive closure for reliable, high-frequency material routing.
• Ni-Hard Pipe Bends: Wear-resistant cast bends with replaceable wear-back plates that significantly outlast conventional pipe materials.

Operating throughout the Great Lakes Region, Wm. Neundorfer & Co. understands the region-specific needs of the concrete industry in our service area of OH, WV, PA, and NY.  We provide more than just equipment; we provide a local partnership.

Through our collaboration with Conveyors Etc., we combine custom design-build capabilities with our comprehensive manufacturer portfolio to deliver a level of local technical support and rapid response that national distributors simply cannot match

Q: Can you design a conveyor system for an existing, cramped facility?

A: Yes. Through Conveyors Etc., we specialize in custom engineering. We can design steep-angle conveyors or bucket elevators to fit into legacy plant footprints where space is a premium.

Q: What is the most effective way to unload cement railcars in the winter?

A: In the Great Lakes region, moisture can cause material to pack tightly. NAVCO pneumatic railcar shakers are the industry standard for breaking material loose and ensuring a clean, fast discharge.

Q: Do you provide installation services for new conveyor systems?

A: Yes. We offer turn-key solutions that include design, engineering, fabrication, and on-site installation and commissioning.