KANSAS CITY, MISSOURI, US — Grain handling industry players are moving ahead with plans to build, improve or expand ship loading and unloading systems, fueling a surge in demand that had been curtailed the last few years due to the combined effects of COVID-19 and political unrest.
Respondents to World Grain’s annual survey said they’ve seen a significant uptick in orders for 2024 and 2025 as customers finally are making investment decisions.
“This surge can be attributed, in part, to the global economy’s recovery following the pandemic,” said Fabio Latino, sales and marketing assistant for Vigan Engineering, based in Nivelles, Belgium. “As agricultural markets stabilize and expand, there is a renewed focus on upgrading and expanding port facilities to handle increased volumes, reflecting a broader trend toward modernization in the grain handling industry.”
Investments are particularly strong in the Middle East, Southeast Asia, and eastern Europe, with good potential in South and North America. Asia is one of the most dynamic regions for new equipment, specifically China and Japan for ship unloaders, said Adrian Hinderling, senior sales executive market segment ship loader/unloader at Bühler.
“As agricultural markets stabilize and expand, there is a renewed focus on upgrading and expanding port facilities to handle increased volumes."
“In China and Japan, rapid economic growth and the increasing need to secure food supplies are driving demand for advanced unloading technologies,” he said. “In Brazil and Argentina, the expansion of agricultural exports and a shifting political landscape are pushing up demand for efficient loading systems.
“These developments are reshaping global grain logistics, increasing transport capacity and influencing international trade flows.”
In developing nations, population growth and a shift in dietary preferences toward wheat-based products is driving the demand for grains and oilseeds. Large vessels can transport the needed commodities to major ports, Latino said, but the difficulty is ensuring the grains reach the end consumers in regions with poor infrastructure.
“This necessitates specialized equipment capable of handling varying capacities and conditions, making the development and deployment of such equipment a crucial aspect of global grain logistics,” he said.
The supply chain continues to present challenges, with war and political unrest necessitating some creative problem solving. The Ukrainian war and the crisis in Israel make it difficult to maintain stable prices for products, said Tomas Kisslinger, managing director for Neuero, based in Melle, Germany.
“We meet those challenges with typical engineering problem solving, division of complex tasks and of course, with good people, client partnerships and patience,” he said. “The experience we have with manufacturing in different countries helps.”
Another challenge has been the inability to sell equipment to Russia due to international sanctions. While Vigan said it has lost a significant market in Russia, it’s also seen new opportunities open in neighboring countries around the Black Sea.
“Although these markets are smaller and often present more temporary or short-term prospects, they have allowed us to pivot our focus and continue operations in the region,” Latino said. “By adapting our strategies to meet the needs of these smaller markets, we’ve been able to maintain a presence in eastern Europe and continue to support grain handling operations in these critical areas.
“We have leveraged our flexibility and adaptability, offering tailored solutions that cater to the unique demands of these emerging markets. This approach has not only helped us mitigate the impact of the war but has also positioned Vigan Engineering as a reliable partner in regions undergoing significant change and uncertainty.”
Meeting customers’ needs
Bühler’s fully mobile Portalink ship unloader, installed in the Japanese port of Kushiro, located on the island of Hokkaido, Japan.
| Credit: ©BÜHLERIt is a continual challenge to meet various regulations and remain competitive, Kisslinger said. Neuero is investing to find a better environmental solution and provide more efficiency.
“For example, in the past where two to three people were required to guide product flow, now you only have one person without special equipment and clear vision,” he said. “Clear vision with precision movements of the loading pipe, also at a high capacity, allow for more efficient loading of the ship hold. Precision movements and robust design allow the system to operate with low-cost maintenance, low wear and ease.”
With rising energy costs, customers are requesting highly efficient equipment and seeking solutions that reduce dust emissions to meet tightening regulations, Bühler said.
“Bühler’s systems effectively reduce dust emissions, ensuring compliance with regulations and protecting the environment,” Hinderling said. “Customers frequently inquire about more environmentally friendly and safer equipment.”
Customers also are concerned about optimizing the performance and reliability of current equipment. Bühler offers Performance Assessment Workshops that identify areas for improvement and implement solutions to enhance operational efficiency and safety.
“These workshops help minimize downtime and extend the lifespan of critical machinery, ensuring smooth, cost-effective operations,” Hinderling said.
Equipment downtime can be costly, so reliability and quick serviceability are essential, said Vigan’s Latino. User-friendly interfaces and efficient operation are critical for minimizing training costs and reducing the risk of operator error.
“With the significant rise in automation and the use of increasingly intelligent machines, systems are becoming more intuitive, further enhancing operational efficiency and lowering the occurrence of mistakes,” he said.
New technology
Vigan is working to address its customers’ concerns with a range of innovations, including the use of new, more durable alloys to improve the longevity and resilience of its equipment. Its systems include smart electronics that reduce power consumption when the equipment is idle, contributing to energy savings.
“We’ve upgraded operator cabins to provide better ergonomics, comfort and visibility, thereby improving the working conditions for operators,” Latino said. “Our equipment now supports online diagnostics via Wi-Fi, enabling remote monitoring and troubleshooting, which reduces downtime and maintenance costs.”
Neuero is continuously improving its equipment with the intelligent belt airlock and auto belt adjust. This component normally was used for alumina and now is being used more in the grain industry, Kisslinger said. The company currently is supplying a new unloader for malt that will use the belt airlock.
“With a self-alignment device, the belt runs in trade under all conditions,” he said. “Compared to regular airlocks, there is no blockage as the housing is flexible, allowing foreign materials to pass through. There is no grain breakage because there are no sharp edges between rotor and housing.”
Bühler also has introduced several innovations, including its new mobile high-capacity ship loader, which offers increased efficiency and reliable operation, said Hinderling.
“We have also reduced the use of hydraulic systems, particularly above water, to lower maintenance costs and enhance environmental sustainability,” he said. “These innovations reflect Bühler’s commitment to meeting current market demands while preparing for the future needs of the industry.”
Following are examples of ship loading and unloading projects that have been completed or are nearing completion.
Polish terminal expansion nears completion
HES Gdynia Bulk Terminal at the Port of Gdynia in Poland is adding intake capacity and flat storage, supplied by Cimbria.
| Credit: ©CIMBRIAHES Gdynia Bulk Terminal at the Port of Gdynia in Poland is nearing completion of a project that includes expanding the current grain terminal intake capacity to 1,000 tonnes per hour and new flat storage with a capacity of 64,000 tonnes.
Cimbria, based in Thisted, Denmark, delivered equipment for the bulk terminal in 2016 and is working with the facility again on the expansion. The project includes a customized intake system with weighing bridges, which will significantly speed up the unloading process. It includes the Moduflex dust-free loading chutes and an underground discharging system and movable and reversable conveyors for a flexible and adaptable solution.
This new system will make for a more efficient receiving and shipping of grain via Panama ships. With the flat storage, the terminal will be able to store grain and soybean meal.
The solution from Cimbria has been designed in close collaboration with the customer. The new warehouse conveyors and handling equipment will contribute to a more efficient handling process.
“After completion, HES Gdynia will be able to offer higher level of quality, safety, and capabilities, providing much-needed space for such a supply constrained agricultural market, underpinning the terminal as the reliable logistic grain partner for our customers,” said Sonia Florczuk, commercial director at HES Gdynia Bulk Terminal.
The Gdynia project is expected to be completed by the fourth quarter of this year. HES Gdynia is one of the largest dry bulk terminals in Poland and is accessible by barge, rail and truck.
Colacem adds unloader for rice
Colacem spa, located in Boselli quay, at the entrance of the port of Savona, Italy, needed rapid installation and a customized solution for a new ship unloader to handle paddy rice, cargo rice and parboiled rice. Vigan installed a NIV 400 ship unloader with a capacity of 400 tph.
The project was completed in 13 months and required meticulous planning, Vigan said. Special handling equipment was used to minimize breakage, particularly for paddy rice. Advanced wear-resistant materials were used to ensure durability.
One of the significant challenges of the project was the narrow dock space, which imposed spatial constraints and logistical difficulties. The dock’s limited width required precise coordination and innovative assembly techniques to fit the ship unloader without disrupting terminal operations.
Despite these constraints, the final assembly was completed successfully, demonstrating Vigan Engineering’s capability to adapt to unique site conditions, Vigan said. The ship unloader also features a gantry with an integrated weighing scale for precise measurement.
SABIC looks to control dust
SABIC replaced a ship loader with Neuero’s KIKO DLH to control dust.
| Credit: ©NEUEROSustainability is a key focus for SABIC, a significant player in the fertilizer industry, supplying customers throughout the Middle East, Far East, Africa and the United States with a variety of agri-nutrient products. When it was looking to replace ship loaders at its facility in Saudi Arabia, it wanted an environmentally friendly solution.
SABIC worked with Neuero for two gantry-type ship loaders, each with a capacity of 700 tph, to handle urea. Urea is the most popular and economical of nitrogen fertilizers, with a higher concentration of nitrogen compared to other solid fertilizers. It can be used in a wide range of environmental conditions on crops such as wheat, barley, rice and corn.
The new ship loaders replaced the existing jet slinger design, which creates dust pollution. The Neuero KIKO DLH, used for the first time with urea, eliminates dust pollution.
“It is always challenging to break old habits,” Neuero’s Kisslinger said. “The reward with following orders opens this market for a cleaner environment.”
