Material Handling Consulting

We made our name solving the most complex bulk material handling problems.

Material Handling Engineering

When undertaking complex retrofit or design engineering, there is substantial risk involved. Will retrofit designs perform as desired? Will installation difficulties create unexpected, costly downtime? A poor design with suboptimal performance can cause numerous issues. Does it have to be fully replaced or can it be fixed?


Bulk material handling operators are seeking engineered systems that not only minimize spillage and dust excursions but those that do so while increasing the duration between major maintenance intervals. While at times these demands are in conflict with one another, Acensium’s experience has shown that diligent inspection and soft goods maintenance, combined with robust initial design, can produce the results these operators seek.


Acensium LLC 3D scanning services and material handling design engineering consultants have worked extensively with Plant Scherer to facilitate retrofit projects and as-built services before, during and after projects. Acensium provides accurate laser-scanned as-built services, modeling engineering retrofit projects. With decades of engineering experience, Acensium couples professional utility-engineering consulting-knowledge with cutting-edge laser scanning, 3D modeling and augmented reality technology with industry-leading results.

Reduce Dust.
Reduce Risk.

DEM for Material Handling Engineering

DEM reduces risk by allowing engineers to design and optimize equipment digitally. These digital designs are then run through simulated scenarios to model real-world performance. DEM even allows you to test scenarios outside of original design conditions (higher flow rate, wet material, different temperatures, higher tonnage, etc). The trial and error process involved in effective material handling engineering can be daunting. Dozens of testing and simulation iterations, often with long simulation rendering times, mean that the process must be completed in a way conducive to meeting tight deadlines. Because of the time-sensitive nature of most projects, Discrete Element Modeling (DEM) simulations become as much art as science, requiring educated decisions on what to simulate and test. Materials may have variable conditions, such as varying water content depending on uncontrollable environmental variables.


Understanding this reality and accounting for it in the model is only possible with accurate data gathering coupled with repeated simulations. Some materials may have critical limitations on some variables, where the material is damaged or destroyed by excessive force, heat or some other environmental condition. Accounting for these variables in the design process is only possible with adequate data-gathering efforts.

Clearly Defined

The single most important part of any material handling project is the definition of scope and expectations. Every acensium project starts with a Functional & Operating Requirements Meeting.

Exactingly Inspected

The best designs will not yield a successful performance outcome if the complex fabrication is not completed within the design tolerances. Is your fabrication correct?

Robustly Engineered

Sound engineering practice begins with the study and mastery of fundamental math and science, but the true perfection of the craft occurs when the engineer applies this learning in the field.

Expertly Installed

“The best laid plans of mice and men often go awry..” – all the planning, engineering, and fabrication could be for naught if the installation crew does not fully understand the project.

Transfer Point Retrofit Key Criteria

Have a transfer point replacement project coming up? Our engineering team has been involved in over 1000 transfer point replacements!

Tripper Room Dust Control

Fighting to control dust in your bunker fill rooms? Seems like everything you do doesn’t even put a dent in the problem? We have a successful formula.

Active Dust Control
Material Handling

Active dust control is a capital and O&M intensive approach to solving your dusting problems. Learn how careful pre-planning and passive dust controls can help reduce risk.

Transfer Chutes

From the simple to the complex, our transfer chutes out perform any other design that has ever been offered to the market.

Crusher Houses

Optimization of Crusher Houses to extend crusher life, minimize fugitive dust, and increase throughput.

Transfer Houses

We have helped configure transfer towers to handle nearly 10,000 tph of material per hour, while passing through 3 splitter gates.

Washdown Systems

Custom designed washdown systems to remove combustible dust from material handling systems.

Mag Separators

Properly configured magnetic separation eliminates maintenance and downtime, while greatly improving performance.

Non-Ferrous Separation

Magnets leave rocks in your material flow. We design custom separation equipment and arrangements to meet your specs.

Acensium Article on 3D Scanning for Project Streamlining and Risk Management Featured in Industry Today

An article by Rowan Connelly, General Manager at Acensium, was recently published by Industry Today. In this piece, Rowan explains how Acensium was able to collaborate with an Installing Contractor for a large North Carolina power plant to streamline project workflow and minimize risk.

Capture savings and reduce risk with 3D digital twins for construction

3D Scanning for construction provides a digital environment that forms a digital basis for project planning, approvals and execution. Each phase of construction can be designed in one combined environment.

How Engineering Firms can Leverage 3D

Millimeter-accurate measurements can be made from a desk instead of onsite, detailed renderings can be delivered to all project stakeholders to make sure every party is in alignment and project risks can be identified with 3D scanning of a new project space.

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!


Learn how digital assets can enrich and improve your process.