Conversion from a Belt Bucket Elevator to a Central Chain Bucket Elevator: An Engineering-Based Solution

5. February 2026

Uncategorized, AUMUND Fördertechnik

Conversion from a Belt Bucket Elevator to a Central Chain Bucket Elevator: An Engineering-Based Solution

At an existing raw meal circulation system, an operator was facing increasing operational issues with a belt bucket elevator installed in 1990. High process temperatures and the material’s particle size led to increased belt wear, rising maintenance effort and reduced system availability.

Engineering Analysis as the Basis for the Conversion

The project started with a detailed technical analysis carried out by AUMUND Conversion Engineering. The objective was to fundamentally assess the existing conveying equipment and to develop a technically robust alternative to the original design.

Based on this analysis, the decision was made to completely convert the existing belt bucket elevator into a central chain bucket elevator. Although almost all conveying components were replaced, this conversion represents one of the clearly defined and technically standardised conversion scenarios: the change from a belt bucket elevator to a chain bucket elevator.

Implemented Conversion Measures

As part of the conversion, the following measures were implemented:

complete conversion from a belt bucket elevator to a central chain bucket elevator
installation of a new central chain with angle links and buckets
replacement of the drive and take-up shafts
continued use of the existing drive unit
integration of PREMAS® 4.0 for chain wear monitoring

The existing steel structure could largely be retained. This limited the intervention in the existing installation and significantly reduced the conversion time.

Technical and Economic Benefits for the Operator

The conversion and targeted process optimisation resulted in a reliable and maintenance-friendly solution, tailored to the actual operating conditions of the plant.

For the operator, this provides clear advantages:
reduced susceptibility to wear
increased system availability
early detection of chain wear through condition monitoring
extended service life of the existing installation

Why Process Optimisation & Conversion Instead of New Investment?

The conversion of existing conveying systems can represent a technically and economically viable alternative to new capital investment. Based on a sound engineering analysis, AUMUND Conversions enables the targeted modernisation of existing equipment and its adaptation to current requirements.

Typical benefits of process optimisation and conversion include:

technological upgrading of existing conveying systems
adaptation of the machine to current design and safety standards
updating of machine documentation
improved process and machine safety
standardisation on AUMUND components with long-term spare parts availability
potential reduction in maintenance effort and downtime
application-dependent contribution to higher energy efficiency

Engineering, Planning and Implementation from a Single Source

Conversion projects at AUMUND are engineering-driven. Each conversion starts with a technical assessment and a sound design carried out by the AUMUND Conversion Engineering team. Based on this, implementation is carried out in coordination with the customer – either by the customer themselves or, upon request, by AUMUND Group Field Service, always adapted to the specific operating conditions on site.

Contact

For technical consultation, feasibility studies and project-related enquiries, the AUMUND Conversion Engineering team is your central point of contact: