May 2025

Breaking Barriers in Bologna

Daniele Sciuto, Euromecc Srl,
explains how an innovative debagging facility in Bologna, Italy, is reshaping the white cement market.

In the world of cement imports, efficiency and flexibility are crucial. Cement producers continually analyse market trends, allocating their exporting capacities to different regions based on expected consumption. However, sudden spikes in demand or shifts in economic conditions require quick strategic changes and rapid adaptation to maintain or gain market leadership.
In recent years, Italy has experienced an increase in cement imports, despite a slight contraction in domestic consumption. This shift has created a complex market environment, where efficiency in logistics and cost-effective packaging solutions play a crucial role. In response, big bags (FIBCs) have emerged as a game-changer, facilitating the handling and transportation of imported cement while offering a practical alternative to traditional bulk terminals.

The challenge of bulk cement terminals
One of the biggest obstacles in setting up a bulk cement import terminal is securing a suitable location and obtaining the necessary approvals. While ports are the natural entry points for bulk shipments, they come with strict zoning laws, environmental concerns, and high infrastructure costs. Securing permits for bulk terminals can take years, with community opposition and bureaucratic hurdles often delaying projects indefinitely.
Big bags, on the other hand, eliminate the need for dedicated bulk terminals. They enable cement to be stored and distributed from inland locations, such as industrial zones and logistics hubs, where planning approvals are far easier to obtain. A basic warehouse equipped with forklifts and bag-cutting stations is often sufficient, making this approach faster, more cost-effective, and far more flexible than traditional bulk handling.
Recognising these advantages, Royal Cement Italia Srl decided in 2021 to establish a big bag import facility in Bologna, strategically positioned to serve the heart of Italy’s construction industry.

The technical solution: a lean and efficient setup
The chosen facility design prioritises efficiency and simplicity, comprising three core components:

• A debagging station for unloading big bags and transferring cement into silos.
• A storage unit capable of holding up to 500 t of white cement.
• A bulk loading station for road tanker distribution.

Debagging station: ensuring a clean and efficient process
The indoor debagging station consists of a twin hopper system, where big bags are delivered via forklift. This setup allows operators to position a second big bag while the first is being emptied, significantly enhancing productivity. For further optimisation, overhead cranes can be added, allowing multiple bags to be handled simultaneously.
A crucial component of this station is its dedusting unit, which ensures that no cement dust escapes into the warehouse, maintaining compliance with health, safety, and environmental (HSE) regulations. Once emptied, the cement is transported via screw conveyors to a vibrating screen, which ensures product quality by filtering out contaminants and preventing waste.
Following the screening process, an additional screw conveyor transfers the cement outdoors to a bucket elevator feeding system. This system is capable of handling up to 55 tph, ensuring a smooth and controlled flow while preventing contamination from moisture or environmental exposure.

Storage unit: optimising space and logistics
The outdoor storage unit was carefully designed to meet specific volume requirements while minimising height. The facility features a 500 t vertical bolted storage silo with a 6.13 mm diameter, allowing for a lower overall height. This design choice also optimised the bucket elevator installation, reducing its required height and, consequently, associated costs.
The bucket elevator, connected to the screw conveyors from the debagging station, efficiently transfers cement into the silo via an enclosed piping system. At the top of the silo, an additional dedusting filter serves both the storage unit and the bucket elevator, ensuring compliance with environmental regulations.

Bulk loading station: downstream distribution
At the discharge end of the storage facility, a 120 tph heavy-duty screw conveyor feeds a loading spout positioned over a weighbridge. Operators access the loading panel via a designated staircase, allowing for seamless cycle start and stop functions. This setup facilitates quick and efficient loading of road tankers, ensuring prompt delivery to construction sites and distribution centres.

Overcoming challenges: engineering precision in a tight space
One of the most significant challenges in this project was the limited available space. Designing and assembling a fully functional setup within a constrained area required highly skilled project management and meticulous engineering.
To ensure a smooth installation, equipment was delivered in a carefully planned sequence to prevent congestion at the site. Factors such as weight, geometry, and structural integrity played a crucial role in determining the installation order.
The silo was the first component installed, with its modular structure allowing for efficient assembly in large sections.
The bucket elevator followed, requiring support from the silo. A larger crane was necessary at this stage to accommodate the extended reach.
Final installations included extraction systems and indoor equipment, followed by fine-tuning before commissioning and startup.

A more flexible future for cement imports
The success of Royal Cement’s Bologna facility demonstrates how big bags can revolutionise cement imports, offering a cost-effective, scalable, quick, and environmentally friendly alternative to traditional bulk handling.
By avoiding the challenges of port-based terminals, companies can establish strategic inland distribution points, reducing infrastructure costs and adapting to market demand with greater agility. After three years of smooth operation, this facility has filled a crucial gap in the Italian white cement market, proving that innovative logistics solutions can drive competitive advantage while meeting industry needs.
For businesses looking to streamline their import operations, bypass regulatory hurdles, and enhance distribution efficiency, big bags offer a compelling solution — one that is shaping the future of cement logistics in Italy and beyond.

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