Home › Mechanical Engineering Services › Cement Equipment Engineering
Home › Mechanical Engineering Services › Cement Equipment Engineering
For kiln, mill, and cooler OEMs and the plants that run their equipment
Keep your kiln line running longer. Free assessment and roadmap.
The challenge
Kiln shells, coolers, and ducts crack as temperatures swing. Without kiln shell cracking analysis, the cracks come back.
Review: Shutdown plan
→
What changes
Our cement equipment engineering uses thermal FEA to find heat stress, so shells and supports last.
How: Thermal FEA →
The challenge
Heat that leaks from kilns, coolers, and ducts costs fuel on every ton you produce.
Review: Energy audit
→
What changes
Heat transfer analysis shows where heat escapes and how to keep more in the process.
The challenge
Abrasive clinker and dust wear chutes, mills, and conveyors faster than you planned.
Review: Wear audit
→
What changes
Wear points are moved, protected, or made easy to replace, so stops are shorter and rarer.
How: Machine Design →
The challenge
Dust and stack limits tighten while fans and filters already run near their limits.
→
What changes
Dust controls are modeled in CFD for your limits, without oversizing the fans.
Kiln, mill, and cooler OEMs and low-carbon startups: we act as your engineering team on the equipment.
Your extra design team.
Get Your Free RoadmapCement plants: we define and design the equipment your process needs, then work with your OEM to deliver.
Your process, our design.
Get Your Free RoadmapPlant and OEM in one design loop, so heat, wear, and emissions are solved in the equipment, not at start-up.
One loop, both sides.
Get Your Free RoadmapBring your own manufacturer, or work with our partner network. We take the designs we engineer as far as you need. We don't manufacture, so we never compete with the OEMs we partner with.
Facts about how we work, not project results. One team engineers your product from analysis to delivery, and calculations carry a PE stamp where required.
01
An equipment design with the thermal and wear data behind it, ready for your next shutdown.
02
Thermal and flow results you review and approve at each gate, before anything is installed.
03
You own the IP by default. When an OEM or partner manufacturer is involved, the contract spells out who owns what.
04
If we missed it in our QC, we fix it. If your supplier can't make the part within three years, or supply dries up, we fix that too.
You send
What we need to start
Drawings or CAD for the equipment
Operating data: temperatures, flows, and tons
Failure history: cracks, wear, and stops
Shutdown windows and plant constraints
Targets: uptime, fuel, or life
→
You get
What you hold at the end
Design: CAD and drawings ready to build
Thermal and flow results you approved
A fix list ranked by value and effort
Fabrication package, ready to quote
Support through shutdown and start-up
We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment.
Find thermal stress and distortion in kiln shells, tires, coolers, and ducts before they crack in service.
Built for the real heat.
Used For
Kilns
Coolers
Ducts
Model heat flow in kilns, coolers, and preheaters, so more heat stays in the process and less fuel is used.
Less fuel for every ton.
Used For
Kilns
Preheaters
Coolers
Design chutes, conveyors, and mill parts for wear and service, so stops are shorter and come less often.
Shorter, rarer stops.
Used For
Chutes
Conveyors
Mills
Rebuild drawings for old mill, kiln, and conveyor parts, fix why they failed, and bring them back to supply.
Parts back in supply.
Used For
Legacy Parts
CAD
Supply
Public benchmark
CFD-guided fan redesigns at a cement plant cut measured shaft power 26–34% (Sustainability, 2025).
What it means for you
The redesign came from CFD models of the flow, and field measurements confirmed it. Our cement plant engineering work on kiln-line equipment runs the same way: model it, change it, and check it against your plant data.
The public record shows what the method can do. What it does for your equipment depends on your constraints, and the free assessment tells you.
Plant, OEM, or both: we set the model, the builder, and the hand-off.
Scope, priorities, shutdown dates, and approval gates.
Design plus thermal and flow analysis, checked in our QC.
Drawings and a package ready for your shutdown.
Start-up support, plant data review, and later changes.
You approve the design at every gate, so nothing that affects function surprises you. If we missed something in our QC, we fix it. If a supplier can’t make a part within three years, we fix that too.
Shutdown coming up? Send the drawings and data. Free roadmap.
Frames, buckets, and wear parts that fail far from any shop, redesigned for impact, dust, and abrasion.
Stop costly downtime.
Applications
Frames
Wear Parts
Crushers
Scrubbers, ducts, and fans designed to your permit limits, without oversizing the system or the fans.
Right-size your controls.
Applications
Scrubbers
Ducts
Fans
Aerospace to data centers: see how one engineering team solves hard constraints across ten industries.
Find the one like yours.
Industries
Aerospace
Mining
Data Centers
Fixed scope for one project. A lower-risk place to start when you want to see our work on your data.
Start with one project.
Fits When
One Project
Fixed Scope
From $35K
Scheduled monthly engineering for recurring needs: drawing updates, ASME calcs, or FEA for each sale.
Work on a set schedule.
Fits When
Monthly
Recurring
From $15K/mo
A dedicated PPS team working your program daily, built for long, multi-year development and testing.
Your program, every day.
Fits When
Daily Work
Multi-Year
From $800K/yr
Gold · One project: a kiln, cooler, or mill part that keeps failing or wasting heat.
Platinum · Ongoing work: engineering support across shutdowns and upgrades.
Diamond · A long program: a dedicated team for a line upgrade or new kiln line equipment.
FEA, CFD, CAD, DFMA, and testing under one roof. Engineering is a team sport, and you get the whole team.
One team, every skill.
Under One Roof
FEA
CFD
CAD
DFMA
Testing
Veteran-owned SDVOSB status gives defense and federal buyers a set-aside path to proven engineering.
Verify our SDVOSB status.
Credentials
SDVOSB
VOSB
CAGE 8ZK73
NAICS 541330
Missed something in our QC? We fix it. Supplier can't make the part within three years? We fix that too.
Support for the long run.
We Fix
Our QC Misses
Supplier Gaps
Supply Chain
We price to the value we deliver, not hours logged. You buy a design that works, not more iterations.
Pay for the result only.
Collections
Gold
Platinum
Diamond
What does your cement equipment engineering cover?
Our cement equipment engineering covers the analysis and design work that hot, dusty, nonstop plants need. We work on the equipment itself: kilns, coolers, mills, chutes, and conveyors. Most plants feel the limits as cracked shells, lost heat, worn parts, and unplanned stops. Each of those starts in the design. Heat swings warp kiln shells and crack ducts. Heat that leaks out costs fuel on every ton. Abrasive clinker wears chutes and mills faster than planned. Dust limits add pressure too: the EPA's Portland cement NESHAP regulates particulate matter, mercury, and other pollutants at cement plants. Each problem found late waits for the next shutdown.
Thermal FEA finds the stresses heat creates in kiln shells, tires, coolers, and ducts. Heat transfer analysis shows where heat escapes and how to keep more in the process. Machine design reworks chutes and mill parts for wear and faster service. Cement kiln design changes are checked against your real temperatures and duty. Fixes are ranked by value and effort, and you approve each one before it is built.
Can you work around our shutdown schedule?
Cement plants fix equipment during planned shutdowns, and those windows are short and costly. Our cement equipment engineering is planned backward from your shutdown dates. A design that misses its window waits for the next stop, which can be months away. So timing matters as much as the design. Rushed fixes cause their own trouble. A part that arrives late, or fits badly, can stretch the stop or force a restart with the old problem still in place. Planned upkeep pays back. The EPA's ENERGY STAR guide for cement making notes that preventive maintenance, such as on kiln refractory, means less downtime over the long term.
The free assessment ranks fixes by value and effort. The roadmap then sets which designs must be ready for which stop, with gates you approve. Each design is checked in analysis before the shutdown. Parts with long lead times are flagged first, so they can be ordered in time. If a fix can't be ready, we tell you early and plan it for the next window.
Can PPS work with our OEM or manufacturer?
Yes. Cement equipment engineering from PPS fits the partnerships that are normal across the cement industry. We work in one of three models. As your OEM partner, we act as your engineering team. Operator-led, we design the equipment and work with the OEM or builder you choose.
When design, build, and test sit with different companies, problems pass back and forth. The builder works from an old drawing, and each party defends its own scope. The Department of Defense's IPPD Handbook organizes programs around integrated product teams for this reason. In a joint program, the plant and the OEM work with us in one loop.
We engineer the design and coordinate the builder in one loop. Bring your own manufacturer, or work with our network of fabricators, machine shops, and test labs. You decide how far we take the design, up to the start of production. We never run production, so we never compete with your OEM. NDAs cover every party, and you own the IP by default, set in your contract.
What do you need from us to start?
To start a project with our cement equipment engineering, send what you have, in any format. That usually means drawings or CAD for the equipment, operating temperatures, flows, and tons, and the failure history. Add shutdown windows, plant constraints, photos, and your targets for uptime, fuel, or equipment life. Old repair and inspection records help too. Missing data is the most common reason engineering projects stall, because a model built on guessed inputs gives a guessed answer. That is why we don't start the work until every data set is in.
Once it is, the first step is a free assessment of your project scope. We confirm what the work can and can't answer, and tell you what is still missing. Then we send a roadmap proposal with scope, targets, and approval gates. Every project is scoped on its own, so the roadmap sets the schedule, not a stock promise. NDAs are available before you share any files. For gaps in material data, NIST material measurement data is a good first stop.
Who owns the design and the models?
You own the design, the drawings, and the models from your cement equipment engineering project by default, as set in the contract. When an OEM or partner manufacturer is involved, the contract spells out who owns what. Some firms keep the models, or license them back to you, so every later change sends you back to them. That locks your product to one vendor and makes design reviews harder, because your team can't open the evidence behind the decisions. You receive the native CAD, the drawings, the simulation model files, and the documented results. Your engineers can then check the work, rerun a load case, or hand the package to a supplier or customer.
We sign mutual NDAs before any of your data is shared, and your files stay in our controlled project folders while we work. If your program has export-control or customer data rules, tell us at the start and we will set up the data handling to match them. For defense programs, the State Department ITAR guidance sets the rules we follow.
What happens if a prototype fails in test?
If a prototype fails in test, we find out why and fix the design. Hard engineering carries unknowns on any project: real loads, material lots, and assembly effects never match a model perfectly. With cement equipment engineering from PPS, you approve the data at each gate. A test result is then checked against predictions you have already seen, not a black box. A failure in test is data. It shows which assumption was wrong: a load, a material property, or a boundary condition. That data improves the model and the design.
When testing is in scope, we plan the test to confirm the margins that matter most. Then we correlate the model to the results, following ASME verification and validation practice. If the miss was ours, because something slipped through our QC review, we fix it. If the test uncovers a condition nobody knew about, we scope the change with you and update the roadmap. Either way, you get a clear answer and a path to a design that holds.
How is cement equipment engineering priced?
We price cement equipment engineering to the value it delivers, not the hours we log. Hourly billing rewards extra iterations, so the cheapest quote often becomes the most expensive project once tooling, rework, and field failures show up. Our incentive is to get the design right the first time. We engage by fit, not as a ladder. Gold (from $35K): you have one project and need help with it. Platinum (from $15K/mo): you have recurring work at a steady rhythm. Diamond (from $800K/yr): you have a long development program, often multi-year.
Gold is never required, and some clients start at Platinum or Diamond. These are starting points, not quotes; your roadmap sets the price. We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment. Our engineering consultant pricing page explains how each collection works in more detail.
Kiln line losing heat or uptime? Send the plant data now.
Send your drawings, plant data, and failure history. We review your project scope in a free assessment and reply within one business day with next steps.
On-site assessments that require travel are quoted separately.