Challenges in Material Handling

What challenges do you see in the industries you serve, and how do you help clients address them?

Robert: Many industries face challenges like handling difficult materials - sticky, dusty, or hazardous substances - meeting stricter environmental regulations, and maintaining efficiency in aging plants. Rising maintenance costs and safety concerns due to spillage and dust add to the complexity.

I help clients address these challenges by focusing on root causes. Whether it’s optimizing material handling systems, improving dust containment, or enhancing equipment reliability, my solutions are always tailored to the specific needs of the client.

Your expertise spans belt conveyors, dedusting systems, and shipping technology. How do you approach problem-solving in these areas?

Robert: I adopt a holistic approach because these systems are interconnected. For example, a poorly designed conveyor chute can cause excessive dust, overwhelming the dedusting system. Addressing just one piece of the puzzle won’t solve the problem.

My process begins with a comprehensive analysis of the issue, examining equipment performance, design flaws, and operational practices. From there, I design solutions that eliminate inefficiencies, minimize downtime, and ensure seamless integration of systems.

I always prioritize sustainability and cost-effectiveness to ensure the improvements have long-term value for my clients.

What do you find most rewarding about working as an independent consultant?

Robert: The ability to make a tangible difference is incredibly rewarding. Helping transform a plant that’s struggling with breakdowns and compliance issues into one that runs efficiently and cleanly gives me immense satisfaction.

Being independent also means I can provide unbiased advice tailored to each client’s unique needs. I’m not tied to selling specific products or services, which allows me to focus entirely on finding the best solutions for my clients.

Their feedback and seeing measurable improvements in their operations are the highlights of my work.

Could you share a particularly challenging project you worked on and how you helped resolve it?

Robert: One of the most challenging projects I handled was for a cement plant dealing with frequent chute blockages and excessive dust emissions. These issues not only disrupted production but also caused non-compliance with environmental regulations.

After conducting a detailed audit, I identified two root causes: a poorly designed conveyor chute and excessive false air infiltration. By redesigning the chute for better material flow and sealing integrity, we drastically reduced blockages and emissions.

We also optimized the dedusting system to align with the new operating conditions. This solution not only resolved the immediate issues but also ensured compliance with environmental standards and significantly reduced downtime.

Robert, could you share a bit about your professional journey and what motivated you to start your consulting business RK Nowa?

Robert Künzi: Certainly. My career spans more than 25 years across various engineering fields, including power, aluminum, cement, and chemical process industries. Early on, I noticed a pattern: core production processes tend to get the lion’s share of attention and resources, while auxiliary systems—like material handling and dedusting—are often sidelined.

These systems might seem secondary, but they are critical to a plant’s overall performance. Neglecting them often leads to unplanned downtime, inefficiencies, and higher costs. Recognizing this gap inspired me to start my consulting business.

My mission is to offer practical, tailored advice that addresses these overlooked challenges, helping companies optimize operations and embrace lean, safe, and environmentally sustainable practices.

What advice would you give to professionals or companies looking to improve their material handling and dedusting systems?

Start by analyzing your existing systems to identify pain points, such as frequent breakdowns, high maintenance costs, or environmental compliance issues. Focus on addressing root causes rather than applying temporary fixes.

Investing in well-designed, integrated systems ensures that handling and dedusting operations complement each other. And don’t hesitate to seek external expertise - an independent consultant can offer valuable insights and solutions that might not be apparent from within your organization.

About Robert Künzi and RK Nowa

Robert Kuenzi, founder and lead consultant, is a mechanical engineer with over 25 years of hands-on engineering experience and a robust network of industry partners.

Before becoming an independent consultant, Robert spent more than 10 years with an international cement manufacturer in Switzerland and India, where he led a team dedicated to developing material handling and dedusting solutions for cement plants.

Prior to his work in the cement industry, Robert held roles as a commissioning engineer for combined power plants and as a process engineer and project manager in the power generation and aluminum industries, where he gained extensive on-site experience.

Thank you Robert for taking your time to share your expertise and project insights with us.

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