ELMEK
Materials Handling Design · Chute & Transfer Point Design

Advanced Chute Design & Optimisation

Engineered for Performance. Optimised for Reliability.

ELMEK provides advanced engineering solutions for bulk material transfer chutes, combining material flow analysis, Discrete Element Method (DEM) simulation, Finite Element Analysis (FEA), and practical mechanical design to improve material handling efficiency, structural reliability, wear performance and maintainability.

Discuss Your Chute DesignExplore Our Engineering Process

Common challenges

Solving Complex Bulk Material Transfer Challenges

Uneven Material Distribution

Off-centre loading causes conveyor mistracking, spillage and premature belt wear.

Excessive Liner Wear

High material impact and abrasion lead to frequent liner replacement and unplanned downtime.

Material Blockages & Build-Up

Poor chute geometry and cohesive material behaviour restrict flow and stop production.

Structural Integrity

Chute body stresses and fatigue under operating loads can lead to cracking and failure.

Dust Generation & Spillage

Uncontrolled flow, air entrainment and poor containment create housekeeping and safety issues.

Maintenance Accessibility

Difficult liner change-outs and restricted access extend shutdown time.

Engineering & simulation

Advanced Simulation. Proven Engineering Principles.

Our wider analysis capability is described on the Engineering Analysis & Simulation page.

DEM simulation video to come
01

DEM Simulation & Material Flow Optimisation

We use Discrete Element Method simulation to study material trajectory, velocity, impact forces, distribution and flow behaviour through the transfer.

  • Material trajectory and velocity assessment
  • Chute geometry optimisation
  • Blockage and build-up investigation
  • Impact and abrasion assessment
  • Receiving conveyor loading optimisation
FEA stress contour or ANSYS video to come
02

Structural FEA & Chute Body Verification

Finite Element Analysis verifies the chute body under operating loads — stresses, deformation, strength and, where appropriate, fatigue.

  • Stress and deformation assessment
  • Strength verification of plates and stiffeners
  • Fatigue considerations where applicable
Wear contour image to come
03

Liner Wear & Service Life Assessment

DEM results combined with established wear models, including Archard's wear law where suitable, support estimates of liner wear rates and indicative service life. Results are indicative, not guaranteed.

  • Liner material and thickness selection
  • Impact zone identification
  • Replacement strategy planning
CFD airflow visual to come
04Optional specialist assessment

CFD & Dust Control Assessment

Where required, CFD can be offered as an optional specialist assessment to investigate airflow, dust dispersion and containment around transfer chutes.

  • Airflow and air entrainment
  • Dust dispersion
  • Containment and extraction review

Our engineering design process

From Concept to Construction-Ready Design

  1. 01

    Existing Installation Assessment

    Review existing drawings, 3D models and site conditions. Brownfield projects may need 3D laser scanning or on-site measurement and modelling.

  2. 02

    Material Properties & Operating Parameters

    Review client-provided material characteristics, throughput, belt speeds, particle size distribution and operating conditions.

  3. 03

    Preliminary Chute Design

    Develop preliminary 3D geometry and perform material trajectory and engineering calculations.

  4. 04

    DEM Simulation & Optimisation

    Simulate material flow, assess performance and progressively optimise chute geometry.

  5. 05

    Structural Assessment & FEA

    Verify chute body strength, deformation and fatigue-related performance where applicable.

  6. 06

    Liner Wear Assessment

    Evaluate material impact, abrasion and approximate liner wear life using suitable DEM wear models.

  7. 07

    GA & 3D Model Review

    Submit General Arrangement and coordinated 3D models for client review, including operations and maintenance requirements.

  8. 08

    Detailed Engineering & Technical Report

    Complete detailed calculations, verification and reporting, subject to client review.

  9. 09

    IFC Documentation

    Prepare final Issued for Construction drawings, specifications and deliverables following approval.

Applications

Chute Design Applications

Model image to come

Conveyor Transfer Chutes

Model image to come

Crusher Discharge Chutes

Model image to come

Screen Discharge Chutes

Model image to come

Hood & Spoon Transfer Chutes

Model image to come

Rock Boxes and Impact Chutes

Model image to come

Bins, Hoppers and Feed Chutes

Deliverables

What You Receive

Deliverables depend on the agreed scope of each project.

  • 01Design Basis and Engineering Calculations
  • 023D CAD Models and General Arrangement Drawings
  • 03DEM Simulation and Optimisation Reports
  • 04Structural Analysis and FEA Reports where required
  • 05Liner Wear Assessment and Material Recommendations
  • 06Fabrication Drawings and Material Specifications
  • 07Issued for Construction Documentation

Contact ELMEK

Improve Your Material Handling Performance

Whether you are developing a new transfer point or addressing ongoing problems with an existing chute, ELMEK can assist with engineering assessment, simulation, optimisation and detailed design.

Discuss Your Chute Design Project