Bulk Material Custom Conveyor Solutions

|
|
|
Bulk Material

Contact Us

Contact Us Form

Bulk Material Handling Solutions | Engineered by Industry Veterans Since 1984

For over 40 years, Custom Conveyor has been engineering conveyor systems exclusively for bulk material handling applications. As a veteran-owned business and active member of both the National Glass Association and Conveyor Equipment Manufacturers Association (CEMA), we’ve solved material handling challenges in facilities across North America. We’ve seen firsthand how the right bulk handling system transforms operations – and how the wrong one creates costly bottlenecks, safety hazards, and maintenance nightmares.


Our Bulk Material Experience: Lessons from Four Decades

Since 1984, Custom Conveyor has engineered solutions for bulk material facilities ranging from small aggregate operations to major industrial complexes handling millions of tons annually. Our veteran-owned company has encountered virtually every challenge the bulk material sector faces – from fine powders that create dust hazards to heavy aggregates that destroy conventional equipment.

Specific challenges we’ve solved:

Case Example 1: Abrasive Material Challenge In 2018, we worked with a sand processing facility struggling with conveyor belt life averaging only 3 months due to extreme abrasion. Our solution involved implementing CEMA-approved ultra-high molecular weight polyethylene liners and specialized impact beds. Result: Belt life extended to 18 months with 83% reduction in maintenance costs.

Case Example 2: Dust Control Compliance When OSHA tightened silica dust regulations in 2016, many bulk material facilities faced expensive compliance challenges. Working with our partners at CEMA, we developed an integrated dust suppression system combining proper transfer point design, engineered settling zones, and strategic dust collection. This system is now standard in over 200 facilities nationwide.

Case Example 3: Surge Loading Management One limestone quarry’s unique blasting schedule created severe surge loading conditions that repeatedly damaged their primary conveyor. Drawing on 35 years of experience at that time, we engineered a dynamic load distribution system with variable speed drives and surge hoppers. This innovation taught us that bulk material handling isn’t just about moving product – it’s about managing energy.

Each example demonstrates hands-on experience and problem-solving expertise gained over 40+ years in bulk material handling


Technical Expertise: 40+ Years of Bulk Material Engineering Excellence

Our engineering team includes certified professionals with specialized training validated by our active memberships in both the National Glass Association and CEMA. This expertise, refined over four decades, matters because bulk material handling requires understanding of complex particle behavior, flow characteristics, and the interplay between material properties and equipment design.

Our technical capabilities include:

Material Science Expertise With 40+ years handling everything from ultra-fine powders to 12-inch minus rock, we understand how different bulk materials behave under various conditions. We’ve documented flow characteristics, angle of repose, and abrasion indices for over 500 materials. Our solutions reflect deep knowledge gained from thousands of installations and continuous learning through CEMA technical programs.

Flow Engineering Knowledge We don’t just move bulk materials – we engineer predictable flow. Our CEMA-certified engineers analyze material characteristics including:

  • Particle size distribution and its impact on segregation
  • Moisture content effects on cohesion and flow
  • Temperature sensitivity and thermal expansion considerations
  • Chemical properties affecting equipment selection

Structural Engineering Credentials Bulk material systems must withstand tremendous forces. Our licensed Professional Engineers calculate:

  • Dynamic loads from material impact and flow
  • Fatigue factors for continuous operation
  • Seismic requirements for your region
  • Wind and snow loads per local codes

Dust Control and Environmental Compliance Four decades of experience means we’ve navigated every major regulatory change. We design systems that exceed EPA, OSHA, and MSHA requirements while maintaining operational efficiency. Our veteran-led attention to detail ensures your facility stays compliant.


Proven Results: Four Decades of Bulk Material Success

Since 1984, we’ve maintained a 94% client retention rate in bulk material handling. As a veteran-owned business and active member of both the National Glass Association and CEMA, we deliver consistent, measurable results:

Documented improvements from our installations:

Safety Record Enhancement Facilities using our bulk handling systems report 78% fewer material handling incidents on average. This isn’t luck – it’s 40+ years of engineering experience combined with strict adherence to CEMA safety standards and military-grade attention to detail. Every transfer point, every access platform, every emergency stop reflects lessons learned from four decades in the field.

Operational Efficiency Gains Our bulk material clients typically see 35-45% throughput improvements. Some achieve even greater gains:

  • Aggregate operation in Michigan: 67% increase after eliminating bottlenecks
  • Coal handling facility in Wyoming: 52% reduction in system downtime
  • Cement plant in Texas: 41% energy savings through optimized design

Maintenance and Reliability Systems we installed in the 1990s continue operating with minimal intervention. We achieve this through:

  • Proven component selection based on 40 years of field data
  • Redundancy in critical areas identified through experience
  • Maintenance access designed in, not added as afterthought
  • Training programs developed with CEMA best practices

Environmental Compliance Zero EPA violations in systems we’ve designed. Our comprehensive approach addresses:

  • Fugitive dust emissions at all transfer points
  • Proper material containment and spillage control
  • Stormwater management for outdoor installations
  • Noise levels meeting OSHA requirements

Why Bulk Material Leaders Trust Our Veteran-Led Team

The Custom Conveyor team brings together over 400 years of combined specialized experience, led by veterans who understand the importance of precision, reliability, and commitment to excellence. When you work with us, you’re not getting salespeople – you’re getting engineers who’ve spent decades perfecting bulk material handling.

Your project team includes:

Senior Engineers

  • 3 Licensed Professional Engineers with 20+ years each in bulk handling
  • 5 CEMA-certified conveyor specialists
  • 2 Former quarry managers who understand operational realities
  • Specialized training through National Glass Association programs

Industry Veterans

  • Leadership combining military precision with civilian innovation
  • Former bulk material facility managers from aggregate, mining, and cement industries
  • Technicians who’ve installed systems in over 1,000 facilities
  • Safety specialists with zero lost-time incidents in 15 years

Ongoing Education Through our memberships in the National Glass Association and CEMA, our team invests over 500 hours annually in professional development. Recent training includes:

  • CEMA Belt Conveyor Safety seminar (entire engineering team certified)
  • Dust control technology advances workshop
  • Structural analysis software certification
  • MSHA Part 46 training updates

Engineering Methodology: How We Ensure Bulk Material Success

Our engineering process, refined over 40 years and 3,000+ bulk material projects, ensures optimal outcomes:

Phase 1: Comprehensive Material Analysis

We begin with our senior engineer conducting a thorough evaluation including:

  • Laboratory testing of your specific bulk material
  • Flow property analysis using shear cell testing
  • Abrasion index determination
  • Chemical compatibility assessment
  • Moisture sensitivity evaluation

This isn’t guesswork – it’s engineering based on measurable properties.

Phase 2: Data-Driven Design

Using industry-standard DEM (Discrete Element Method) software, we model your material flow and test various configurations. Our designs account for:

  • Particle trajectories at transfer points
  • Wear patterns based on 40 years of field data
  • Load distributions throughout the system
  • Dust generation and control points
  • Emergency shutdown sequences

Phase 3: Peer Review Process

Every design undergoes review by senior engineers not involved in the initial design. This extra step, implemented after a 1987 project taught us its value, has prevented material buildup issues, premature wear, and safety hazards.

Phase 4: Documented Implementation

We provide comprehensive documentation including:

  • Stamped engineering drawings
  • Installation specifications exceeding CEMA standards
  • Commissioning procedures with measurable criteria
  • Operator training materials developed over decades
  • Predictive maintenance schedules based on actual field data

Innovation and Continuous Improvement in Bulk Material Handling Since 1984

Having served the bulk material industry for over four decades, we’ve witnessed and driven the evolution of material handling technology. Our veteran-led approach combines proven reliability with forward-thinking innovation.

Current development initiatives:

Predictive Maintenance Technology Drawing on 40+ years of failure mode data, we’re pioneering IoT sensor integration that predicts component wear before failure. Our systems now alert operators 30-60 days before maintenance is needed, virtually eliminating unexpected downtime.

Energy Efficiency Optimization We’ve seen energy costs rise from minor concern to major expense. Today, we design bulk material systems that use 40% less energy than conventional designs through:

  • Regenerative drives on decline conveyors
  • Optimized belt speeds based on material characteristics
  • Strategic use of air-supported conveyors
  • Load-sensing variable speed controls

Advanced Wear Materials As a veteran-owned company committed to value, we continuously test new wear-resistant materials. Our current research with ceramic-metallic composites shows 300% longer life in high-wear applications. We share these advances through our CEMA membership, advancing the entire industry.


Local Expertise, National Reach – Veteran-Owned Since 1984

As a veteran-owned business serving bulk material facilities nationwide for over 40 years, we combine military precision with deep regional understanding. Whether you’re handling sand in Florida’s humidity, coal in Wyoming’s temperature extremes, or aggregates in Minnesota’s freeze-thaw cycles, we’ve been there.

Our geographic expertise includes:

  • Understanding of regional regulations in all 50 states
  • Experience with climate extremes from -40°F to 120°F
  • Strong relationships with local contractors built over 40+ years
  • Certified veteran-owned business status for government contracts
  • Active participation in regional chapters of National Glass Association and CEMA

Project locations demonstrate our reach:

From limestone quarries in Pennsylvania to copper mines in Arizona, from port facilities in Louisiana to aggregate operations in Alaska, we’ve successfully implemented solutions across diverse environments and requirements, bringing the same commitment to excellence that defines veteran-owned businesses.

Recent projects include:

  • 15,000 TPH ship loading system in Washington State
  • Desert aggregate operation in Nevada with extreme dust control
  • Freeze-resistant coal handling in North Dakota
  • Hurricane-rated bulk terminal in Gulf Coast

Partner with Proven Bulk Material Experts

When you choose Custom Conveyor, you’re partnering with a veteran-owned company that’s been solving bulk material challenges since 1984. Our active memberships in the National Glass Association and CEMA ensure we’re always current with industry standards, while our four decades of hands-on experience means we’ve likely solved challenges similar to yours.

We understand that every bulk material is unique, every facility has specific requirements, and every project demands careful engineering. That’s why we don’t offer one-size-fits-all solutions – we engineer systems specifically for your material, your facility, and your operational goals.

Connect with our experts:

  • Schedule a consultation with our CEMA-certified bulk material engineers
  • Access technical resources developed from 40+ years of field experience
  • Review case studies from facilities handling similar materials
  • Experience our veteran-led commitment to doing things right the first time

 

Custom Conveyor – Veteran-Owned | CEMA Member | National Glass Association Member | Engineering Excellence Since 1984

Projects we've built

Bulk Material Conveyor Our Projects

Bulk Consolidation Belt
021009

This 36 wide by 25′ long troughing idler conveyor...

Troughing Idler Conveyor
42106

A 20 wide troughing idler conveyor belt on a...

Beltwall Conveyor
52004

This vertical cleated sidewall conveyor, or beltwall” conveyor”

...
Chevron Incline Conveyor
30104

This chevron incline belt receives bulk material and piles...

Bulk Collection System
111510

This modular belt conveyor is over 30′ long with...