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Robert Kuenzi Consulting

Your partner for material handling, dedusting and shipping technology

Core Area and Aim of Focus

  • To receive, blend, transport, store and dispatch bulk materials between manufacturing processes – reliable, without restrictions & losses at lowest costs and without fugitive dust emissions.
  • To unload/load bulk materials from ships/barges/trains/trucks with highest flexibility, without demurrage charges and without fugitive dust emissions.
  • Spillage and dust reduction initiatives: Technical support -organisational development – cultural changes.

This allows manufacturing/distribution units to be(come) “lean”, cost efficient and compliant with environmental regulation.

Lean manufacturing

Opportunities For Manufacturing Units

  • To unload/load bulk materials from ships/barges/trains/trucks with highest flexibility, without demurrage charges or waiting time and without fugitive dust emissions.
  • To transport materials between manufacturing processes at full capacity -without manpower, chute blockages or re-handlingand without fugitive dust emissions.
  • To pack bulk materials into bags, at promised weights, without waiting times, stabilized for the transport, protected against ambient conditions and without fugitive dust emissions.
  • To avoid spillages and dust causing excess wear & maintenance costs, cleaning costs and compliance issues.
  • To train the workforce to identify and solve problematic issues.

Services: In bulk material handling, dedusting and shipping/ dispatch technology

Services offered:
For new (green field) projects

During project definition phase:
  • Designing/reviewing plant mass-flow and flow-sheet.
  • Sizing and selecting equipment.
  • Defining scope of project for tendering.

During project selection and execution phase:

  • Reviewing technical offers and advising in selection.
  • Reviewing detailed data during project phases.
  • Inspecting critical equipment in workshops.

During project closure phase:

  • Reviewing installation during erection/commissioning phase and identifying contractual deviations.
  • Monitoring performance guarantee tests.
  • Optimizing operation costs after project closure.

Services offered:
For existing (brown field) projects

  • Executing automatization/optimization and debottlenecking assessments on site.
  • Providing technical due diligence for merger and acquisitions.
  • Supporting capacity increase/feasibility projects.
  • Capacity building and workforce training.

Examples: Typical opportunities with value addition

1. Excess spillage & dust generation:
  • Premature equipment damages, production losses, working environment, environmental compliance, cleaning and repairing downtime and costs.
Excess spillage & dust generation:
Dust affected plants:
Dust emissions
2. Inefficient metal separation:
  • Reduced mill capacity, excess roller wear and damages, vibrations and possible gear-box failures, logistics for contaminated reject material (involving heavy vehicles, manpower and products)
Metal separation in auxiliary transport equipment
3. High inbound and outbound handling cost with low automation:
  • Manual port unloading/loading and transport involving manpower and heavy equipment with re-handling at different storage locations without automation.
Inbound and outbound logistics
4. Reduced production capacity due to auxiliary equipment limitations:
  • Reduced grinding capacity due to conveyors, chute blockages, unexpected break down, high bucket elevator Amp’s or air-slides restrictions.
Downtime of main equipment due to auxiliary transport and dedusting equipment
5. Downtime of main production equipment due to auxiliary equipment.
  • Frequent raw mill stoppages due to unexpected belt conveyor break-down’s.
Weak link in manufacturing
6. Targeted raw material quality not achieved.
  • High lime-saturation/fluctuations due to insufficient blending/mixing in the process chain.
ty variations due to mateial handling equipment
7. Excess wear on equipment:
  • Frequent patch work on conveyor chutes and duct works (causing also wear on surrounding equipment as well as high cleaning costs) with limited manpower requirement.
Frequent wear on equipment
8. Operational and organizational efficiency:
  • Permanent manpower requirement to keep production alive at bin/hopper extraction and conveyor chutes blockages as well as extra maintenance and cleaning jobs.
Permanent Manpower and chute blockages
9. Material dispatch (bulk/bags) limitations or demurrage charges:
  • Waiting times for (customer’s) truck’s to receive purchased products or waiting time to unload raw materials causing very costly demurrage charges.
10. Extreme Seasonal Conditions:
  • Conveyor chute blockages during cold winter or rainy monsoon season hampering production and requiring extra manpower and efforts.
Extreme weather conditions in auxiliary transport systems


We are internationally connected with other service & product suppliers in complementary fields.

Clinker cooler
Hartmut Meyer Clinker Cooler Consulting

Energy concepts and studies:
ILF Consulting Engineers

Holzinger consulting

Kawalek Consulting GmbH
APBP Consulting GmbH

Port and new clinker production lines:
Global Bulk Technologies S.L.: GlobBULK Consulting