SMT Shipping increased their handling rate from 1000 tonnes per hour to 1250 tonnes per hour after their first month.

That’s a 25% increase in productivity!

SMT Shipping had 3 grabs available for bauxite, but started exploring the best possible grab solution for their new iron ore transhipment.

It was a challenge to even consider buying a new grab, but the new grab dominated all the other grabs

SMT achieved results to be proud of:

• The immense productivity increase in their continuous transhipment process lead to a Return On Investment period of under 3 months.
• Zero breakdowns after transferring 6 million tons in the first year and easier maintenance because of direct access from the ground.
• A strengthened partnership that already opened doors for future projects to tackle the unique challenges of open sea operations.

I’m happy to share Marc Smeets’ story with you today. Let me know what you think and if this was helpful.

Download SMT Shipping’s case study and boost your productivity here.

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As a port operator, regular maintenance of your grabs is essential to ensure optimal performance, maintain productivity, and minimize downtime.

However, with numerous responsibilities, maintenance can often be overlooked. When a grab breaks down unexpectedly, it will lead to substantial downtimes and consequential it will have impact on the lay time of the ship.

Grabs, though durable, endure varying degrees of wear depending on the materials handled. Components like shells and knives are in contact with bulk material and require regular maintenance. Neglected maintenance may lead to substantial costs and significant operational issues, which makes regular maintenance planning crucial. By investing in preventive maintenance and keeping essential spare parts on hand, operators can avoid these risks and ensure smooth, uninterrupted operations.

In this blog, we uncover the price of neglected maintenance and share advice to keep your grabs in top condition.

The costs of unplanned maintenance and downtime

Regular maintenance of your grabs is a key factor to avoid the costs of unplanned maintenance and downtime. Without timely, preventive maintenance, several issues can arise.

A grab can start losing its load, causing bulk material to spill over the quay or fall into the water, resulting in expensive losses and environmental issues. A leaking grab cannot be used until it is repaired, which can result in several days of downtime in case there is no redundancy in the grabs.

If a breakdown occurs while a ship is being loaded or unloaded, it can bring the entire operation to a standstill. You would need to find a replacement grab quickly or face significant delays. In the case of transshipment, delays are even longer due to the lack of infrastructure to rapidly get materials and/or engineers on board. Besides the cost of lost productivity and the work and materials needed for repairs, downtime can also incur demurrage charges. Demurrage rates for bulk carriers can range from $10,000 to $20,000 per day: the impact of downtime on demurrage is not to be underestimated.

Best practices for grab maintenance

The best strategy for avoiding costly downtimes and ensuring the longevity of your grabs is regular lubrication, which is generally heavily underestimated. This should be a disciplined part of your maintenance routine as it reduces wear on points of rotation and extends the grab’s lifespan.

Nemag grabs are equipped with a centralized greasing system, making this task easier and safer. This system allows fast and simple greasing of all moving parts and eliminates the need for dangerous climbing. More information on the type of grease and the recommended lubrication frequency can be found in your operation and maintenance manual.

Figure 1 – Centralized greasing system

In addition to lubrication, other types of proactive maintenance are crucial, such as checking and replacing closing and hoisting wires, inspecting pivot points, and ensuring the integrity of cables and guides and visual inspection for cracks in the grab structure. The frequency and type of maintenance required depend on the bulk material being handled; for example, handling wheat may primarily require lubrication, while more abrasive materials like iron ore necessitate extensive upkeep.

Because spare parts often have a delivery time, maintaining a stockpile for unexpected situations is essential. Having essential spare parts readily available ensures prompt issue resolution and helps avoid extended downtimes.

While proactive maintenance can address common wear and tear, human errors can lead to severe damage to components like pivot points, cables and wire guides. These errors can result in sudden failures and extended downtimes, amplifying the operational and financial impact.

In short, investing in preventive maintenance and keeping essential spare parts on hand, is a very small cost compared to the significant expenses of unexpected/unnecessary downtimes and repairs, shutting down the entire operation.

The importance of stocking spare parts and choosing originals

Having spare parts in stock is essential to maintaining operational continuity and avoiding costly downtime. Wear and tear, or even operator errors, can cause grab failures that necessitate immediate repairs. Without readily available parts, a minor issue could halt operations for days, sometimes costing tenfold or even a hundredfold more than the parts themselves. Investing in spare parts is an investment in operational security, much like an insurance policy that prevents expensive disruptions.

Some companies hesitate to invest in spare parts, seeing it as an unnecessary expense. However, the consequences of not having critical components readily available far outweigh the initial costs. Therefore we support a healthy maintenance policy by offering reduced pricing on spare part bundles in the case of a grab purchase. Investing in spare parts is also investing in operational reliability.

What’s the benefit of using original spare parts versus third-party parts?

Original parts ensure quality and reliability. They meet the original standards and will have the longest lifespan, leading to lower risks and less frequent replacements. Additionally, modifying non-original parts to fit takes more time, increases downtime, and can potentially shorten their already inferior lifespan even further: hence investing in original parts is always the best.

Standardized components from Nemag are designed for durability and reliability. Ensuring you have a stock of these essential parts mitigates risks and keeps your operations running smoothly. Always choose original parts to guarantee quality and performance, and avoid the pitfalls of using inferior, imitation parts.

Nemag strives to use grab components, such as bearings and plate materials, that are internationally standardized and widely available, allowing you to source replacement parts locally without hassle. Ensuring you have a stock of these essential parts mitigates risks and keeps your operations running smoothly. Always choose original parts to guarantee quality and performance, and avoid the pitfalls of using inferior, third-party parts.

Proactive maintenance: prevention is better than cure

In conclusion, regular maintenance of your grabs is crucial for optimal performance, productivity, and minimizing downtime. Key practices include disciplined lubrication, proactive maintenance checks, and having essential spare parts on hand. Regular lubrication, facilitated by Nemag’s centralized greasing system, significantly reduces wear and extends the lifespan of your grabs.

Investing in original spare parts ensures reliability and prevents costly disruptions. Neglecting maintenance or using inferior parts can lead to substantial operational and financial impacts.

Want to know the best maintenance strategy for your specific situation?

Feel free to contact us if you have any questions. In a free consultative call, we will provide tailored advice to ensure your grabs operate at peak performance to reduce downtime and avoid costly disruptions.

Extra: Maintenance checklist to increase your operational reliability

1. Read the manual: Start by thoroughly reading the Operation and Maintenance Manual. This manual contains:

• Descriptions and overview
• Safety
• Installation
• Operation
• Appendices (drawings, forms, inspections, additional datasheets)
• Maintenance schedules
• Maintenance procedures
• Transport and storage
• Technical data
• Troubleshooting

2. Follow maintenance and operating instructions: Adhere to guidelines (for example, lubrication and maintenance frequency).
3. Lubrication: Regular lubrication is the best preventive maintenance.
4. Monitor your grab: Visually inspect and listen for unusual sounds. Address issues immediately.
5. Stock spare parts: Always have spare parts available to prevent costly downtime. Unforeseen delays can extend delivery times.

Implementing these practices ensures your grabs operate efficiently and reduces the risk of expensive disruptions. For more information, consult your manual or contact Nemag for support.

The post Effective Grab Maintenance: From Hidden Costs to Reliable Operations appeared first on Cargo Connexion.

Breakbulk Americas is the region’s largest trade event for all those involved in the project cargo, dry bulk cargo and breakbulk industry. Read this blog why you should visit, a must-do tip, opportunities at Breakbulk Americas and more.

This annual event takes place in Houston, Texas, from 15-17 October 2024, and brings together 6000+ attendees, 300+ exhibitors and 450+ global shippers.

It welcomes global sector leaders, including decision-makers from leading energy companies and EPC’s, as well as regional specialized service providers.

Visit Breakbulk Americas if you want to:

1. Discover trends and the latest breakbulk opportunities
   The two-day conference program is a good opportunity to understand the trends shaping future project opportunities, to stay ahead of the curve with your business.
2. Get to know perspectives and lessons learned from peers and competitors
   Presented failures and technological advancements can open up new opportunities for efficiency and cost savings.
3. Expand your project cargo, dry bulk and breakbulk connections
   Attendees will have the chance to engage with leading carriers, freight forwarders, equipment companies, and port terminals, opening doors to new markets and logistical solutions. Connect before the event on LinkedIn. Most used hashtags are #breakbulkamericas #bbam2024 #breakbulk

Must visit at Breakbulk Americas: The Rustic After-party

If you visit the event then we highly recommend to join the After-party at the Rustic on Tuesday 15 October 20:00 – 23:00.

Opportunities presented at Breakbulk Americas 2024

Leading breakbulk, dry bulk and project executives will provide key insights into the latest business and trade intelligence, as well as delve deeper into key markets, sectors and issues affecting the whole supply chain.

Gain insights on key topics and trends with Main stage presentations:

• Breakbulk Fleet Update
• Energy Investment: What To Expect
• The Aging Breakbulk Fleet in Times of Increasing Demand and Regulatory Uncertainty
• Fleet Capacity: Planning for the Future
• Energy Trends and Opportunities
• Mining, Big Tech, Chips & SMRs: A New Ecosystem of Project Opportunity
• Navigating Project Logistics Volatility
• Closing the Talent Gap

Visit Nemag at Breakbulk Americas 2024

At the Nemag stand, Stand B33, you’ll have the opportunity to ask questions surrounding your unique situation and receive customized advice to help you boost your dry bulk unloading productivity.

Understanding that every location and application comes with its own unique challenges, we commit to delving deep into your operational context, and helping you build a tailored solution with the optimal grab crane combination to increase your productivity.

Another client we helped is SMT Shipping. They have benefited from a 25% productivity increase, and this even resulted in a return on investment period of 70 days.

Read the productivity boosting case study.

The post Opportunities and insights at BREAKBULK AMERICAS 2024 appeared first on Cargo Connexion.

15 – 17 October you will have the opportunity to visit the region’s largest trade event for the project cargo and breakbulk, Breakbulk Americas.

Prepare your visit to Nemag at Stand B33:

• Productivity boosting dry bulk grabs
• Insights and opportunities at Breakbulk Americas 2024
• SMT Shipping case: “We had an ROI period of only 70 days”
• Effective Grab Maintenance: From Hidden Costs to Reliable Operations

Reserve a personal appointment to meet Nemag

The highest grab quality with the lowest maintenance costs per ton transferred. Plan a meeting to consult your dry bulk handling productivity and make the most of your Breakbulk Americas visit.

The post NEMAG AT BREAKBULK AMERICAS appeared first on Cargo Connexion.

Our customer, SMT Shipping, has achieved significant transhipment advancements, particularly in West Africa on the TSV Conakry Pearl.

This region presents a unique challenge due to its shallow shores, extending 10 to 20 meters in depth for up to 10 miles. To be profitable, you will have to ship your cargo with colossal ore carriers. These cape-size vessels can export up to 200,000 tonnes.

However, these fully loaded enormous vessels, 18 meters in depth, cannot approach the shore. The traditional solutions, like constructing extensive jetties or dredging long channels, are economically unviable. This is where SMT Shipping’s expertise comes into play.

The post CASE STUDY \ FROM CHALLENGE TO CONQUEST: SMT SHIPPING’S JOURNEY TO A 25% PRODUCTIVITY BOOST appeared first on Cargo Connexion.

The post FROM CHALLENGE TO CONQUEST: SMT SHIPPING’S JOURNEY TO A 25% PRODUCTIVITY BOOST appeared first on Cargo Connexion.

MORE THAN 20% PRODUCTIVITY INCREASE FOR BRAZILIAN LOGISTICS COMPANY WITH THE NEMAX GRAB.

The post Nemag BV – Case Study appeared first on Cargo Connexion.

Headquartered in Convent, Louisiana, Associated Terminals (AT) is the leading stevedore and terminal operator on the Lower Mississippi River and beyond. It operates fourteen midstream river anchorage facilities in the region as well as additional dockside and on-site facilities. “When we first visited AT in 2018, we presented them with a 3D-printed model of our innovative, award-winning nemaX dry bulk grab and they were immediately interested,” explains Rudy Bovée, account manager at Nemag. “They next decided to trial the grab in practice for a month as part of the nemaX world tour. Shortly thereafter, they placed an order. The nemaX simply sells itself!”

Of course, Associated Terminals is not the only terminal to have adopted the nemaX; the dry bulk grab among other things offers versatility, cost-effectiveness, efficiency and ease of maintenance. However, Rudy and his team are particularly proud of the fact that Associated Terminals decided to opt for a Nemag product. Rudy: “AT’s mission, core values and vision perfectly align with our Passion for Performance. Like Nemag, it highly values customer relations and is always looking for ways to innovate and improve operations. After years of development and cooperation between engineers, customers and users, it is really great that the nemaX exceeds everyone’s expectations. To have a customer actually confirm this is a great source of pride for us at Nemag. Especially such a unique customer as Associated Terminals, with its strong emphasis on midstream transloading activities and the use of floating cranes.”

High productivity, low maintenance 

Shortly after commissioning the nemaX in 2019, AT was already achieving the promised productivity increase of 13% and sometimes more. It has also experienced many of the other benefits of the grab. For example, the fact that the nemaX has far fewer moving parts substantially reduces the need for maintenance. Furthermore, it is able to handle 20% more cargo with the same closing cables, further boosting the cost-efficiency of the grab. “Even if the nemaX would have the same productivity as the clamshell, we would still opt for the nemaX, purely based on the operational advantages it offers,” says Zeljko S. Franks II, Senior Vice President of Associated Terminals.

CAPEX and OPEX

When assessing the financial aspects of a grab, two elements are key: the asset investment costs (CAPEX) and the operating expenditure (OPEX). Bulk terminals with clear insight into maintenance costs have concluded that the total maintenance costs of a grab constitute a more significant factor than its asset investment costs. Calculated over the grab’s lifespan, the average asset investment costs of a four-rope grab amount to around 1 eurocent per tonne of cargo transferred. In terms of grab maintenance costs, this can however be as much as 2 to 3 eurocents per tonne of cargo handled.

Minimum downtime

“The nemaX will immediately bring down costs, but other advantages such as maintenance do not become apparent until after a couple of years,” explains Rudy. “Especially when transloading on the water, it is important that the cranes can continuously operate and that downtime is kept to a minimum. For customers such as AT, ease of maintenance is therefore crucial. Since operations take place from a floating pontoon on the Mississippi, any maintenance work will have to be performed right there. So, the less maintenance, the better.”

Long-term partnerships

Associated Terminals handles a highly diverse range of cargos, ranging from dry bulk such as grains, minerals and coal to windmills and project cargo. The nemaX is currently only used for iron ore pellets. Close cooperation with AT and a continuous focus on improvement and innovation will however make it possible to deploy the grab for other types of bulk as well. “We are proud that our grab helps AT to boost productivity and lower the costs,” explains Rudy. “Together with them, we are currently assessing which other commodities might benefit from the nemaX. We do this in close cooperation and based on trust. After-sales is just as important as sales. This is how we build long-term partnerships. In that respect, we are proud to say that AT has placed an order for a second nemaX grab, which will be delivered in January 2022!”

Innovative design features

Regular wear and tear can never be fully prevented, but the nemaX allows you to achieve substantial savings in terms of maintenance. This significantly helps to reduce operational expenditure and downtime, crucial in view of the pressure on handling rates that terminals are experiencing due to overcapacity in the dry bulk sector. Through exhaustive computer simulations, the nemaX offers numerous key innovative design features. The most important ones are:

Minimal number of moving parts

The nemaX design features a minimal number of moving parts: only 2 sheaves and 70% fewer moving parts than in a comparable clamshell grab.

Only 2 main pivot points

The nemaX has only 2 main pivot points with high quality spherical roller bearings. In comparison, a comparable clamshell grab with slide bearings features 12 main pivot points.

Durable closing cables

The way in which the hoisting wires have been reeved reduces flexing along the sheave blocks by 75% compared to a 2 x 5-part clamshell grab. Metal fatigue in the closing cables is reduced proportionately, resulting in a longer operational lifespan for these cables. And nemaX’ unique operational design minimises the clogging and wear of sheave blocks and closing cables and significantly extends the lifespan of the closing cables.

Closing cables are easy and safe to switch

The anchor points of the closing cables are located at an accessible working height, making it easy and safe to reeve in new closing cables without needing to set up an elevated work platform of scaffolding.

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