Polysius
High plant availability.
Increased safety & operational efficiency.
Extended service life.
Stockyard Technology is an integral part of an efficient cement production.
Stockyard technology is a key element of efficient cement production and a critical factor for stable plant performance. Reliable stockyard systems support continuous operation and directly influence overall operational performance in cement plants.
Material handling inefficiencies rarely occur in isolation. Changes in raw material properties, as well as in crushing, grinding or kiln operation, have an immediate impact on stockyard performance, blending quality and material flow. Aging equipment, limited automation and insufficient homogenization often result in higher OPEX, unstable process conditions and increased safety risks. These effects reduce plant efficiency and negatively affect long-term cement production performance.
thyssenkrupp Polysius offers fully integrated stockyard and material handling solutions across the entire cement production value chain. From stackers and reclaimers for bulk material storage and homogenization to precise and controlled feeding systems for downstream processes, these solutions are designed to improve material handling efficiency, stabilize operations and support reliable cement plant performance.
UP TO
30%
OPEX REDUCTION
UP TO
25%
production increase*
UP TO
100%
UP TO
40%
UP TO
0%
Pre bins required
*These measures only make sense in combination with increased mill and kiln capacity.
Stockyard Technology Portfolio
- polysius® belt stacker
- Controlled stacking of bulk materials
- High stacking rates
- Different stacking methods are available
- Suitable for various bulk material storage layouts
- polysius® bridge reclaimer
- Continuous reclaiming of bulk materials
- Suitable for materials such as limestone and coal
- High reclaiming capacities
- Designed for homogenization and blending with excellent pile activation
- polysius® (semi) portal scraper reclaimer
- Continuous reclaiming of bulk materials
- Suitable for limestone, coal and urea
- High reclaiming capacities
- Compact solution with one- or two-boom configuration
- polysius® side scraper reclaimer
- Continuous reclaiming of bulk materials
- Suitable for limestone, coal and gypsum
- High reclaiming capacities
- Cost-effective solution for storages with several bulk materials
- Circular stacker and reclaimer
- Storage and homogenization of bulk materials
- Suitable for materials such as limestone
- High blending efficiency
- Endless / continuous pile system with compact footprint
- Stockyard Technology Automation Systems
- Fully automated stacking and reclaiming
- Reduced operating effort
- Lower OPEX
- Maximum operational safety
Your Key Benefits – measurable impact
Up to 25% production increase
A production increase can be achieved through re-engineered reclaimers, optimized rake designs or upgraded drive systems. These improvements significantly increase stacking and reclaiming rates while keeping existing structures largely unchanged. As a result, higher material handling performance can be realized without major structural modifications to the stockyard.
Up to 100% personnel-free operation
In stockyard technology areas, fully automated stacking and reclaiming systems eliminate the need for personnel in hazardous zones. This level of automation allows continuous operation without manual intervention and significantly improves operational safety. At the same time, it reduces direct human exposure to heavy machinery and material handling processes.
Up to 40% higher availability
Higher availability is achieved through stable and automated material flow across the stockyard. Automated operation minimizes unplanned shutdowns and reduces process interruptions. This leads to improved overall reliability of the stockyard technology and supports consistent operation of downstream processes.
Up to 0% pre bins required
Direct mill feeding from circular blending beds or storage eliminates the need for pre-bins. This results in reduced blockages and a more compact plant layout. By avoiding long conveyors and additional bins, the material handling system becomes simpler and more efficient while maintaining reliable material flow to the mill.
Case Study
Fully Automated Stockyard Technology
in Turkey
thyssenkrupp Polysius drives digital transformation in stockyard technology through full stockyard technology automation.
At a cement plant in Turkey, thyssenkrupp Polysius implemented a fully automated additive and corrective stockyard (incl. automated pile change and first pile cut), setting a benchmark for safety and digitalization in bulk stockyard technology. The installation included advanced sensor technology, Wi-Fi-based communication, real-time stockpile management and the integration of an Anti- Collision Module (ACM). All stacking and reclaiming operations are now controlled centrally from the control room, eliminating the need for personnel in hazardous areas.
KEY BENEFITS
- Complete removal of personnel from hazardous stockyard technology zones
- Centralized, automated operation with full process transparency
- Increased safety, availability and operational efficiency
- Stockpile-management system for an optimized raw material management
FAQ
How is the homogeneity of raw materials ensured in storage?
Automated stockyard systems (stackers and reclaimers) use specialized stacking methods like Chevron stacking to achieve ideal homogenization. This consistency is the foundation for a stable kiln process. Our fully automated bridge reclaimers ensure high efficiency with minimal personnel requirements.
Can existing stockyard systems be modernized without replacing everything?
Yes. Modernizations will be tailor-made solutions. Whether you need the replacement of individual components or a major upgrade such as completely new chain scraper system – we deliver exactly what your operation requires.
Depending on your requirements, our goal is always to keep the impact on the existing equipment as minimal as possible.
Learn more about optimizing your plant: Modernization Portfolio Deep Dive
In a rapidly evolving industrial landscape, staying competitive means getting more out of the assets you already have. During our upcoming 30–45 minute virtual session, we will show how targeted modernizations can unlock hidden performance potential across your plant—boosting throughput, improving efficiency, and reducing OPEX.
Join our experts from thyssenkrupp Polysius as they provide a compact, high‑value overview of modernization levers across the entire process chain: crushing, raw grinding, clinker grinding, pyroprocessing, and laboratory automation.
YOU’LL GAIN INSIGHTS INTO:
- How modernization audits reveal hidden inefficiencies
- What typical performance increases look like
- Which upgrade paths deliver the fastest ROI
WHAT TO EXPECT:
- A practical modernization overview
- Real improvement examples from global plants
- Q&A with our specialists
Ralf Steigüber
Proposal Manager
Get your Whitepaper & Book your Modernization Portfolio Deep Dive
About us
thyssenkrupp Polysius is one of the leading suppliers of technologies and automation solutions for the decarbonization of the cement and lime industry and, increasingly, for other industries. With more than 160 years of experience, we set standards in the development of innovative technologies and services, as well as a comprehensive and customized service offering that enables sustainable and economical production.
Our services are not only tailored to our own products, but also cover installations from third-party suppliers. Thanks to close cooperation with customers and partners, we are able to meet the specific challenges of our customers and offer them optimal service. This special commitment, coupled with decades of expertise, makes thyssenkrupp Polysius a reliable partner on the road to a sustainable future.
Level Up Your Plant 2026 | Imprint | Data Protection | Cookie-Einstellungen