DRY BULK Warehouse Management

// 15 September 2022 @ 14:24


Think Different…Think Smart when handling your dry bulk material in your warehouse using Telestack’s Warehouse Systems

Managing the storage of your dry bulk materials in warehousing can be one of the most difficult tasks to achieve effectively within your port. The ever-changing needs and requirements of the modern world have made this more difficult than ever. 

The need to upgrade older warehouse storage facilities is apparent in many ports globally, however, the cost, time, and limited space available have minimised the feasibility of this in many cases. This emphasises the need for ports to think differently and work smarter to lower their cost per tonne and maximise the heights/reach of the current infrastructure which is of key importance in these scenarios. Even those ports which have high-capacity storage facilities cannot maximise their capacity as the infrastructure or equipment there cannot capitalise on this height and space, without significant investment in a fixed storage conveyor/handling system. These fixed handling systems can sometimes be limited further, as the current warehouse structure is not suitable for the additional weight/infrastructure needed to install the fixed systems. This has led many operations to simply use existing equipment, most notably wheel loaders with long-range pushers.

Traditional Grain Pushers


The use of pushers/grains pushers in warehousing is very common as it is an addition to the common handling process of normal wheel loaders, however it comes with its problems and issues. Most notably are the costs involved in handling the material and ‘pushing’ the material up these stockpiles increasing fuel consumption by approximately a further 60% on common usage methods. The cost of fuel/diesel is increasing significantly, increasing the costs of this process.

Also, when handling such materials as grains, with diesel spillage common from wheel loaders, consistently driving on the material can contaminate the entire feed material. As well as degrading the material when driving over material, affecting the quality, and increasing the fines/dust in the material ultimately reducing the value of the material. 

 The TS 42 Radial Telescopic Warehouse Stacker - An alternative to a Grain Pusher


In these changing market demands, Telestack has devised solutions to solve these problems. Telestack has introduced a TS 42 warehouse stacker for a valued customer in Europe to solve their issues when stockpiling grains/cereal products in their warehouse. The TS 42 radial telescopic warehouse stacker offers a unique material handling solution to provide a fully agile direct feed stacker (From wheel loaders) and is specifically designed to work in the confines of a warehouse, where mobility is key.

Flexibility in dry bulk stockpiling


The telescopic conveyor has a large low-tail 20m³ hopper (fed from 3 sides via wheel loaders) and can reach into each corner of the warehouse. Its manoeuvrability allows for maximum stockpiling capacities within tight warehouse applications.



The radial, telescopic and luffing (up / down) facility of the unit allowed the operation to fully utilise the entire space. The push-down gullwing radial wheels with internal drives allow the machine to radial left and right. The key difference in using the TS 42 warehouse stacker is that the full capacity of the warehouse is utilised, even in areas with restricted stockpile height compared to using a traditional grainpusher with a maximum reach.

In addition, the automatic PLC stockpiling system reduced the equipment required, labour and the initial capital investment required led to a significant reduction in cost per tonne along with a much safer and greener operation.

The Warehouse Stacking Process with Telestack solutions


The process is simple - the self-propelled TS 42 tracks towards the rear of the warehouse and the radial wheels are lowered into position, the inner conveyor is extended and the conveyor remains in its lowest position initially. The trucks bring the material inside the warehouse and the wheeled loaders load the material into the hopper. An operator manoeuvres the machine (left/right, in/out) to fill the warehouse to maximum capacity. The TS 42 warehouse stacker can radial to 270° and with precise control it allows the operator to maximise the volume of product in the warehouse. Stockpiles heights of 14m (45ft 9”) can be achieved whereas a wheeled loader would struggle to achieve a height higher than 6m which means the capacity/ heights can be increased by 100%+ in most cases.

One of the main benefits is that the TS 42 design is that it can be moved whilst still operating so no time is lost due to movement or relocation. The self-propelled TS 42 with its crawler tracks (steel flat shoes thus no damage on concrete or asphalt surfaces) and inline travel wheels allow the unit to be quickly and easily relocated in the warehouse. Dual speed tracks allow for fast relocation over longer distances and the slow speed option allows for slow relocation in the warehouse while continuing to operate. The machine can move forward even with the material in the hopper and with the belts running. This process is repeated until the warehouse is at a maximum stockpile capacity, utilising as much space within the existing infrastructure. 

The Operator has total control of the machine from the control panel or remote control to position the product and the unit can be connected to the local electric power supply for reduced operating costs. In addition, warehouse stockpiling is much cheaper and safer using a radial telescopic compared to a wheel loader. The mobility of the unit also means that the conveyor can be moved from warehouse to warehouse easily for multi-location / multi-product stockpiling and can even be used outside the warehouse for general stockpiling.

Range of Warehouse Systems to fit all sizes 


Within this range of solutions, Telestack has developed other more compact solutions to meet the heights, widths and space requirements of any warehouse. The need to be flexible within very limited space is key to ensuring flexibility when handling your dry bulk material in the warehouse.

WS 30 Wheeled Warehouse Stacker


The wheel-driven radial stacker version complete with an integrated hopper, to be fed from the wheel loader, offers an alternative for the smaller warehouse where the TS 42 warehouse stacker may be too large to operate. The WS30 Wheeled Warehouse Stacker is a self-propelled unit for easy movement and transition up and down the centre of the warehouse. This allows for stockpiling heights up to 10m (30ft), to ensure it can reach beneath the structure of all the differing types of warehouses. The unit can be used to stockpile directly (fed from wheel loaders) or may be fed directly via grain hatch of trucks (not designed for dumping) so the unit can stack directly from the truck, eliminating the need for the wheel loader. This unit can be moved from warehouse to warehouse via a tow hitch from the rear. It can also be electric or hydraulically driven, depending on the power sources available within the warehouse.  



All of these units can be packed into 40ft containers, which ensures easy and cost-effective transport around the globe. On site, assembly can be as little as 1 - 2 weeks. Conveying material is the most cost-efficient and environmentally sound method of material transfer as it not only reduces dust levels, noise levels and carbon footprint but it also eliminates the high costs associated with dump trucks and shovel haulage. It has an increased production capacity and a lower capital investment. 

Telestack are specialists in the complete design, manufacture, installation and commissioning of mobile bulk material handling systems. We have a global proven record in a range of applications including mining and quarrying, stockyard management, ports & inland terminals, power stations, rail yards, steel mills, cement kilns and many other bulk material handling industries. Telestack offer a wide range of solutions along the logistics chain from the pit, to port to plant.