Reliable service restores peak performance for IFFCO’s Siwertell ship unloader

At IFFCO’s Paradeep terminal, operational reliability is essential for maintaining efficient bulk material handling. The terminal’s Siwertell 790-D screw-type ship unloader plays a critical role in handling materials such as rock phosphate and sulphur, supporting continuous production flows.

After more than 12 years of operation and over 18,000 running hours, key components in the vertical conveyor system had reached a point where replacement was necessary. To maintain performance, ensure reliability, and minimize operational risk, IFFCO initiated a comprehensive upgrade of the vertical conveyor.

Where precision meets operational reliability

The vertical conveyor is a core component of the ship unloader, and its performance directly impacts unloading capacity and operational stability. In this case, several components had remained in service since the original commissioning, making their replacement both technically demanding and operationally sensitive.

The project was further complicated by a limited maintenance window between vessel operations. The available shutdown period was significantly shorter than standard requirements, placing high demands on planning, coordination, and execution.

To ensure adherence to OEM standards and enable a rapid return to service, IFFCO chose an EPC (Engineering, Procurement and Construction) solution delivered by Bruks Siwertell, including full technical supervision.

A structured EPC approach

Bruks Siwertell executed the project through a complete EPC delivery, combining engineering expertise, component supply, and on-site supervision. Installation was carried out by a qualified local contractor, working under the close guidance of experienced Bruks Siwertell service engineers.

Extensive pre-assembly work was conducted ahead of the shutdown period to reduce downtime. Conveyor tubes, screw sections, and associated components were prepared in advance, enabling efficient installation once access to the equipment was secured.

The scope of work included dismantling of existing vertical conveyor components, installation of new transport tubes and screw assemblies, installation and alignment of bearings, handling and installation of the vertical gearbox, and complete system alignment.

Throughout the project, strict adherence to original design specifications and quality standards ensured technical accuracy and long-term reliability.

“Following the replacement of the vertical conveyor components, the screw unloader is operating smoothly without vibration and is performing almost like a new machine,” says Mr. B. K. Raul, Chief Manager (Mechanical), IFFCO Paradeep.

Reliable execution under tight timelines

The presence of OEM expertise during critical installation and alignment phases was a key success factor. With structured planning, clear scheduling, and strong technical guidance, the project was completed within the constrained timeframe.

“The Bruks Siwertell supervision team provided excellent technical support. The work was executed with careful planning, clear scheduling, and strong technical guidance,” adds Raul.

Following installation, the system underwent full commissioning. The vertical conveyor performed as expected during trials, allowing the ship unloader to be returned to operation without delay.

Improved performance and operational reliability

The result is a significantly improved machine, both in terms of performance and reliability. The ship unloader is now operating smoothly and efficiently, handling rock phosphate at unloading rates of approximately 1400–1500t/h, even under challenging conditions such as high moisture content.

Through the replacement of critical components and execution under OEM supervision, IFFCO has effectively extended the operational life of its equipment while restoring near-original performance levels.

“Overall, the replacement of the vertical conveyor components and the supervision provided by Bruks Siwertell have significantly improved the performance and reliability of the ship unloader,” concludes Raul.

For more information, read the customer case here.