Robust Engineering

If you haven't pounded the bricks,
you have no business designing the new system.

Even well-designed equipment can have difficulty with material variations if they weren’t accounted for in the design. These variations often lead to operational problems resulting in lower productivity, higher wear rates, increased maintenance costs and costly shutdowns. Engineers can simulate numerous variables with DEM that model real-world behavior. This allows an engineer to find the design that implements the optimum angles, increases flow or mass maximums, reduces downtime due to malfunction, decreases waste or leverages the optimal materials.

The strength of 3D modeling & simulation is unquestionable, that is why every project is scanned and modeled. A model is only as good as the information put into it, though. If the inputs aren’t right, the results will not be right – regardless of what modeling software you use. The long-term proven success of a model through use is the only way to ensure success. It is a mix of science and art – there is never a single given ‘right answer’ in engineering. Honest engineering involves recording data, testing, performing an accurate analysis of performance and admitting where improvements can be made in modeling or design. Acensium uses models for coal chutes that have years of proven effectiveness, but we still record data and revise our modeling as an ongoing process. The observation and recording phase is even more important when developing models for new materials.

Scan. Model. Plan.
Reduce Risk.

Keep It Simple but Elegant

If your engineer cannot explain what they are about to design for you on a whiteboard in 30 seconds or less, they are probably overthinking it! The best designs are simple, fundamental works of art.

The best material handling engineers are creative and design-oriented but are not afraid to wear a hard hat and a pair of steel-toed boots. They pound the material stockyards to truly understand your problems.

Knowledge in. Success Out.

The old saying, “Garbage in, Garbage out,” is applicable to every modeling system. When we model your material flow using discrete element modeling, you are receiving over 15 years of field qualified modeling output. If your designer has not field verified at least 100 installations against their modeling, how do they know their modeling is true and accurate? We inject our knowledge into every model we build so you yield success!

As-Built Records

A retrofit system cannot be designed without accurate background drawings or models. We develop accurate baselines for every project.

  • HD Laser Scan Point Cloud Capture
  • Conversion of Point Clouds to Solid Models
  • Rich Visual Basis for Conceptualization

Discrete Element Modeling

DEM (Discrete Element Modeling) is a useful tool in the right hands, and a horrible tool in the wrong hands.

  • Tested Material Characteristics
  • Applied Field Results Feedback Loop
  • Realistic Limitations Exposed and Discussed


In the old days, teams discussed their projects together as a group and produced a solution acceptable to the team, not just the engineer.

  • All Design Aspects Completed in 3D
  • Team Involvement throughout the Process
  • Web Reviews Expand Review Access
What could you do with a high definition scan of your next project? Our millimeter-accurate scanners capture reality in very high detail. Want to learn more? We’re ready to help. Let’s discuss your project today!


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