Process Evaluation & Optimization for Bulk Material Handling Systems
When a process has been running for years, it usually works – but it doesn’t always work well. Legacy systems get expanded over time, equipment gets swapped out, controls get patched, and suddenly you’re operating a “Frankenstein” line: disjointed components, inconsistent performance, rising downtime, and operators forced to compensate with workarounds.
GQI’s Process Evaluation & Optimization service is built for exactly that reality. Led by a GQI Field Engineer Consultant, we document what you have, identify what’s holding you back, and deliver a practical, step-by-step path to improved reliability, throughput, and efficiency – without disrupting production.
Why Process Evaluations Matter for Legacy and "Frankenstein" Systems
Even well-run operations can quietly lose performance over time. Common indicators include:
Throughput caps you can’t explain (or can’t push past)
Unplanned downtime becoming “normal”
Frequent adjustments to keep product within spec
Excessive wear, recurring part failures, or screening issues
Dust, spillage, cleanup time, and material loss
Training challenges because “only a few people know how it really works”
Our goal isn’t to sell a one-size-fits-all fix. It’s to create clarity: what’s happening, why it’s happening, and what changes will deliver the biggest gains.
What You Get with GQI's Field Engineer Consultant Approach
This engagement goes beyond a quick walk-through. GQI acts as an extension of your team—bringing OEM-level insight and real-world field experience to build a complete operational picture.
Your Field Engineer Consultant can provide:
Full system documentation of your current process and equipment configuration
OEM-level evaluation of machinery performance, wear points, and integration gaps
Operator collaboration to capture real workflows, not just what the drawings say
A clear, prioritized set of optimization recommendations
A structured plan for reliability improvements and long-term maintainability
This is especially valuable when original documentation is missing, outdated, or spread across vendors, binders, and tribal knowledge.
Optimization Opportunities We Commonly Identify
Each site is different, but process evaluations often surface improvements in areas like:
Material flow & transfer points (reducing hang-ups, spillage, and dust)
Screening performance (screen selection, blinding, efficiency, and uptime)
Conveying reliability (mechanical or pneumatic performance and bottlenecks)
Process integration (mismatched equipment, controls, or legacy add-ons)
Maintenance access & safety (serviceability that prevents shortcuts)
Downtime drivers (repeat failures, chronic wear zones, and root causes)
We prioritize recommendations based on impact—so you can tackle quick wins now and plan smarter upgrades later.
A Prescriptive Path - Tailored to How You Operate
Some customers come to GQI for a one-time evaluation. Others want a roadmap, documentation package, and ongoing support. We keep this service intentionally flexible, because every facility has a different mix of equipment, staffing, risk tolerance, and production requirements.
Whether you need clarity on a single line or a full-facility reliability plan, we’ll meet you where you are – and build a smarter path forward.
Start a Smarter Project
If your bulk material handling system has grown over time and performance, reliability, or consistency has suffered, GQI can help you regain control of the process.
Ready to improve throughput, reduce downtime, and modernize the way your system is maintained?
Click below to connect with our team and start the conversation.
Need Equipment, Parts, or Support?
GQI is ready with solutions built for your operation - no guesswork, just results.