ELEVATOR WITHOUT EXCESSIVE COSTS: HOW TO BUILD A NEW FACILITY SO THAT IT IMMEDIATELY GENERATES PROFIT

Author: Olexander Suprun, journalist

Today, the era of extensive growth in the agricultural market has finally come to an end. Ten years ago, the success of an elevator was measured by its capacity, but now it is determined by its operational efficiency and ability to generate margins in conditions of constant external risks. With its experience in comprehensive design and installation, “CHIEF” asserts that a new elevator is no longer just a physical structure, but a financial asset designed as a fortress against economic threats. If built in the old way, the facility will be unprofitable even before it pays for itself. I decided to figure out why a modern elevator should be “smart” from the outset, and why choosing a partner like DCC “CHIEF” can be the key to profit.

Ukraine’s agricultural market is undergoing a transformation caused by war, global competition, and the energy crisis. According to the Ministry of Agrarian Policy and Food of Ukraine, grain exports in 2024 increased by 15% compared to the previous year, but logistics and energy costs eat up to 40% of the margin. Previously, the success of an elevator was measured in tons stored: “The more, the better.” But now the focus is on the cost of processing one ton. If a traditional elevator costs 1-1.5 UAH per ton to maintain (including gas, electricity, and downtime), a modern “smart” facility reduces this figure to 0.7-0.9 UAH. This is not science fiction — it is a reality offered by integrators such as DCC “CHIEF”.

Let’s compare: a classic elevator built in the 2010s often suffers from inefficient dryers that “devour” gas and spoil grain due to uneven heating. The result? Quality losses of up to 5-10%, which reduces the selling price by 10-15% on international markets. In contrast, new projects, such as those implemented by DCC “CHIEF”, integrate technologies that save resources from day one. “We don’t just build walls — we create a system where every element works for profit,” comments Olexander Chumachenko, director of “CHIEF”, in a conversation with me. Analytics show that investments in such facilities pay off in 3-5 years, while older models may remain in the red due to rising gas prices.

Why build now? Because the market won’t wait. Moving to western borders and river routes (Danube, Odessa) makes logistics 20-30% more expensive, and competition with Brazil and Argentina is forcing Ukrainian farmers to optimize every link in the chain. Without a modern elevator, the harvest risks sitting idle in queues, losing moisture and quality. According to FAO experts, global demand for grain will grow by 10% by 2030, but only efficient players will survive. Building a new facility is not an expense, but an investment in sustainability.

One of the main “enemies” of profit is an outdated dryer. In traditional models, grain is subjected to constant heating, which not only consumes gas (up to 1.5 m³ per ton), but also damages the product: cracks, reduced germination. DCC “CHIEF” offers a modern alternative – DRY-MX series dryers with “Phase of Rest” technology. How does it work? The grain passes through hot air, then “rests” in a special chamber where moisture naturally migrates to the surface. In the second cycle, the dryer consumes less energy because the moisture is already accessible.

The comparison is striking: a standard dryer consumes 1.2-1.5 m³ of gas per ton, while DRY-MX consumes only 0.8-1 m³, which means savings of up to 30%. Analytics from DCC “CHIEF” on real objects show that for a 50,000-tonne elevator, this saves 1-1.5 million UAH per season. Plus, the grain retains its quality: the moisture content is uniform, without damage, which allows it to be sold at a 5-10% higher price. “This is not marketing — it’s physics,” explain the company’s engineers. Compared to competitors, such as Chinese budget models (savings of only 10-15%, but with the risk of breakdowns) or European ones (up to 40% savings, but the price is +50%), DRY-MX is the golden mean.

Traditional elevators with slow silos and manual control are turning into “bottlenecks”. DCC “CHIEF” solves this problem with CR-type silos for fast loading. Thanks to the gravity system, grain is loaded 60-70% faster: from 100 t/h to 200-300 t/h.

SCADA, an automated control system, serves as the “brain” of the entire system. It provides visualization of all technological flows and allows the operator to control the entire complex from a single panel. This is not just monitoring: it tracks temperature, humidity, and conveyor status in real time. Predictive maintenance warns of breakdowns 24-48 hours in advance, reducing downtime by 80%. SCADA does not just record breakdowns, it analyzes vibrations and the temperature of elevator and conveyor bearings, warning technical staff of possible malfunctions in advance. This eliminates emergency downtime, which is the biggest financial risk during the season.

Let’s compare it with analogues: basic PLC systems (local) provide only basic control, without forecasts, while full-fledged SCADA systems from Siemens or Honeywell are expensive (from €100,000). DCC “CHIEF” integrates affordable versions with customization, reducing costs by 20-30%. To illustrate with an example: an elevator without SCADA loses 5-10% of its time on manual checks, while with SCADA, efficiency is 99%. Market analytics based on USDA data show that effective logistics increase profits by 15-20%.

Why is DCC “CHIEF” the ideal partner? In the elevator construction market, agricultural specialists face a dilemma: a cheap local manufacturer (which does not have access to advanced energy-efficient technologies) or an expensive international giant (which delivers slowly, has high prices, and expensive service). DCC “CHIEF” occupies a unique position as an integrator, combining the best of both worlds: international quality standards with local speed and responsibility. As an integrator, “CHIEF” takes care of everything on a turnkey basis: from project development (taking into account energy efficiency), supply of modern equipment, commissioning, to installation of metal structures. This eliminates equipment incompatibility, which in 30% of cases leads to rework.

Building a new elevator today is not a luxury, but a modern necessity. With “CHIEF”, you get not just a facility, but a “smart factory” that brings profit from the first grain. Gas savings, fast logistics, and intelligent management are the keys to competitiveness. That is why strategically minded agricultural specialists choose “CHIEF” for their new high-tech facilities.

ELEVATOR WITHOUT EXCESSIVE COSTS: HOW TO BUILD A NEW FACILITY SO THAT IT IMMEDIATELY GENERATES PROFIT

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