Optimus Solutions
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Optimus Process Solutions is a process engineering consultant business focused on the science behind the process. We have expertise in process services related to rotary kilns, rotary dryers, ball mills, and other rotary equipment. We got our start by responding to request after request for help from individuals that were given the responsibility for the process and need help in meeting emissions standards, reducing energy consumption, improving product quality and increasing process capability.
Spotting kiln crank (or dogleg) 🔍
This video shows a severe case of crank and breaks down one of the very first warning signs you need to look out for. The distortion on this particular shell was so extreme that it requires a shell section replacement to fix the issue and get things back in alignment. ⚙️🛠️
Watch to see the movement for yourself and learn what to look for on your own equipment!
If you know what to look for, the warning signs of misalignment are right there in front of you.
If your maintenance team is currently battling any of these headaches, it might be time for an alignment survey:
⚙️ Gear Wear & Vibration: Accelerated tooth wear or vibrations coming from your gear.
🚨 Bearing Failures: Temperature spikes and premature housing failures.
📐 Tire/Roller Contact Issues: Uneven or too little face contact between your roller and tire.
💥 Shell Cracks: Severe fractures usually caused by mechanical stress.
When these signs appear, it’s time to stop guessing.
Our team removes the guesswork. We conduct comprehensive alignment surveys to assess your equipment’s structure, delivering the exact data and diagnostic insights needed to catch the root cause.
05/25/2026
This Memorial Day, we pause to honor and remember the brave individuals who made the ultimate sacrifice for our freedom. Their courage and dedication will never be forgotten. Wishing everyone a safe and meaningful day.🇺🇸
05/07/2026
Out with the old, in with the "like new." ✨
Our team just recently finished refurbishing this hot oil heater, ensuring it’s ready for years of reliable service ahead. Check out the before and after! 👇
04/28/2026
Is your equipment trying to tell you something? ⚙️⚠️
Not every problem can be solved with a standard fix. You should consider a Finite Element Analysis if:
✅ You’re dealing with persistent cracks or structural failures.
✅ You’re about to make major design modifications.
✅ Your "tried and true" repair methods aren't stopping the issues.
Don't wait for a catastrophic failure. Let’s get the data you need to protect your equipment. Reach out to our team for more info.
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12711 Townepark Way
Louisville, KY
40243
