Optimus Solutions

Name: Optimus Solutions
Address: 12711 Townepark Way, Louisville, KY, 40243, US
Telephone: (844) 880-5822

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Optimus Solutions

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Optimus Solutions is a process engineering consulting business focused on the science behind the pro

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.

10/20/2026

Our engineers have been putting Drum Drift to work! Our team has been installing these sensors to help plant operators monitor drum position in real time, right from the control room.

By replacing manual field checks with continuous monitoring, operators can spot movement early, reduce component wear, and keep production running smoothly.

More visibility into drum movement means fewer surprises in the field.

10/13/2026

Rotary equipment rarely fails without warning. It gives you signs if you know where to look 🚩

Heavy loads and constant heat take a toll over time. If you’re noticing any of these red flags, your kiln or dryer may be running out of alignment:

🚨 Shell cracks
🔊 Vibration from your gear
💥 Frequent bearing failures
📐 Contact issues between your tire and support rollers

Operating out of alignment puts extra stress across your entire unit, leading to sudden breakdowns and costly downtime.

An alignment survey beats an emergency outage every time. A thorough survey gives you the hard data you need to plan maintenance on your terms, not the unit's.

10/12/2026

To all our Canadian team members, partners, and friends—Happy Thanksgiving!🍁

We are so grateful for our hard-working team and the amazing partners who make what we do possible. Hope everyone has a wonderful day celebrating with family and friends! 🍂✨

10/08/2026

it's been a busy week in the field! ⚙️ Our team is across the country conducting alignment surveys, troubleshooting burners, and visiting customers.

From precision measurements to complete burner service, no two visits are ever the same and we love seeing the team tackle it all.

09/24/2026

What’s actually happening inside your rotary dryer? 🔍

If your flighting design isn't tailored to your specific material, you’re likely losing heat transfer, leading to wet material, decreased production, and high fuel costs.

That’s where a 3D flighting study comes in. By 3D printing different flighting and testing it with your process material, we identify the exact design needed to boost heat transfer before you invest in a full redesign.

By modeling the cascade of material inside the drum, you can:
🔸 Maximize airflow contact for total heat transfer 🔥
🔸 Cut down fuel consumption per ton of product ⛽
🔸 Stop material buildup & optimize retention time 🕐

When you optimize the flighting, you optimize the whole process.

09/22/2026

How much time does your team waste trying to solve persistent vibration or alignment issues without the right tools?

Without accurate data, maintenance is just educated guesswork. TomTom-Tools are designed specifically to give plant engineers and maintenance managers instant, ultra-precise data on unit health.

When your team has the right tools in hand, you locate root causes faster, avoid unnecessary parts replacements, and keep production on schedule.

Upgrade your plant's measurement capabilities with tools built specifically for rotary equipment.

Details on TomTom-Tools are in the caption below 👇

09/17/2026

From a pallet of random parts to a fully operational system. 🛠️🔥

When a job throws a pile of unusable components and an unexpected site power outage your way, you pivot. Our team stepped in to transform the setup and successfully install this hot oil heater.

Key Highlights:
🔸 Converted the existing burner from oil to natural gas
🔸 Sourced parts and plumbed the fuel train directly to the burner
🔸 Installed the control panel, wired all components, and powered through the outage
🔸 Delivered full on-site commissioning support to get the customer up and running

09/10/2026

What’s running the show behind your combustion system? 👀

Your controls are the brains of the operation and when they’re outdated, unreliable, or not optimized, they can make everything harder than it needs to be.

We service your entire combustion system and can help you optimize existing controls or replace outdated systems, so your equipment is easier to operate and more reliable day after day.

09/07/2026

Happy Labor Day!

Today, we celebrate the people who make progress possible. From developing new ideas to solving complex challenges, we’re proud of the talent, dedication, and hard work that drive our team forward every day. 👏

09/03/2026

Ever wonder what excessive shell ovality could be telling you about your unit? 👀

As your unit rotates, the shell naturally flexes. A little flexing is normal, but too much can put additional stress on the shell over time.

That repeated flexing can contribute to:
• Shell fatigue
• Distortion
• Cracks

But shell ovality can also offer insight into your refractory. Changes in shell flexing may indicate areas where the refractory has deteriorated or shifted.

That’s why monitoring and trending shell ovality over time is so important. Keeping an eye on changes can help you spot developing issues before they become much bigger, and more expensive, problems.

Address

12711 Townepark Way
Louisville, KY
40243

Telephone

(844) 880-5822

Website

https://optimusps.com/

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