iLenSys provides a range of design engineering services to meet customer requirements for both unit and bulk material handling equipment design. We offer end-to-end product design services from conceptualization to the final product. Our design solutions consist of broad applications of solid-state electronic control, scanners and other control devices to provide on-line or “real time” data on the status of equipment and materials in an operation.

Design Services

Design of Structures
Selection of Drives and Standard Parts
Design of Bearing and Shafts
Part/Assembly/GA Drawings
Creation of Digital Manuals
Flow Rate Calculations
FEA and Manual Calculations
Safety Considerations
Industrial Automation
Extended Reality Solutions


Steel Plant

Power Plant

Cement Plant

Aggregate & Quarry

Shipping Industry


Services to EPIC

Food and Packaging



  • CEMA, IS 11592 (Conveyor design).
  • ISO:3684 – Conveyor belts (Determination of pulley diameters).
  • BS:2573 I, II – Crane Design.
  • ISO:5048, ISO:5049 (Mobile equipment continuous handling).
  • DIN 22261 & AS4324.1 – Mobile Equipment for Continuous Handling of Bulk 
    Equipment (Excavators/spreaders).
  • FEM Standards 2.131/2.132 – Rules for the design of Mobile Equipment for Continuous 
    handling of Bulk Materials.
  • AWS D1.1 – Structural Welding.
  • Mechanical / Structural / Hydraulic / Pneumatic / Electrical and Electronics Engineering.
  • Analytical Modeling and FEA – (Static/Dynamic).
  • Progressive Computer-aided Design, Development, And document support.
  • Product Optimization.
  • Control Designing & PLC , HMI Automation.
  • Field Failure Analysis And Design Support.
  • Digital Manual Preparation.

Conveyor Design

Conveyor Design
  • Designing of Troughed Belt Conveyor.
  • Design Components used for Horizontal Conveyor, Inclined (Uphill) Conveyor, Steep Conveyor & Declined (Downhill) Conveyor.
  • Design of Conveyor drive power, Gearbox and Coupling for Conveyors.
  • Design of Head and Tail Pulley, Belt Scrapper, selection of Idler sizes, their location & bearings.
  • Selection of Belt for Conveyor  as per Material Characteristics like Lump size, Density etc.
  • Design of inlet and outlet chute with Skirt Board.
  • Provide Conveyor with all Safety Switches like Belt Sway, Speed Switch, Protection, Track Metal Detector etc.

Apron Feeder

  • Design of Impact tray, Carrying Rollers, Return Rollers as per Material Characteristics.
  • Frame Design through FEA and Manual Calculations.
  • Selection of Bearings Sealed for life, Purgeable dust seal & spherical roller bearings with Cast steel Plummer block, high precision link chain/ crawler chain, Manganese alloy sprockets.
  • Variable speed Hydraulic Pump Drive & Hydraulic Power pack for Pulley & Dribble Drag Chain.
  • Overload Safety Device, Speed Sensor, Apron weigh Feeder and Automation control.
  • Centralized or Manual Lubricating System.
Apron Feeder


  • Design of Tripper Structure to support Conveyor components, Long travel Drive, Cable Reeling Drum etc.
  • Design of tripper components as per Material Characteristics like Head/Drive Pulley, Bend Pulley, Take-ups, Scrapper, Belt alignment.
  • Design of Chutes and Flap Gate with Actuators.
  • Design for Long Travel Drive Power, Gearbox, Brake & Coupling Wheel, Axle, Plummer Block.


  • Design of heavy Structure like:
    • Equalizer beam & bogies
    • Undercarriage
    • Superstructure & Pylon
    • Reversible boom
    • Counterweight arm and tie arm
    • Counterweight structure
    • Electrical machine air-conditioned platform
    • Operator’s cabin with hydraulic & mechanical controls
    • Bucket wheel
    • Maintenance Walkway and access to platforms etc.
  • Design of balancing of machine

Belt Feeder

Belt Feeder
  • Designing the sizes and shapes of Vibrating Feeders and recommended frequencies with corresponding range of amplitudes.
  • Design of weld free bootable steel Structure as per material characteristics like Fabricated Plate Framework mounted on either base or Suspension spring mounted.
  • Selection of Screen Openings for Single or Multiple Deck, wire Cloth or Polyurethane Screen Media, etc., & Tensioning rails.
  • Selection of drive, helical springs, suspended or cable, air mount, eccentric mass, shaft, flywheel, “V” belt, sheave or pulley and special heavy-duty taper roller antifriction bearings.
  • Entire assembly securely locked with tightly fitting SAE machined huck bolts.


  • Design of Heavy Structures Like
    • Portal Leg with Bogies
    • Shift able Discharge Conveyor
    • Counter Weight Structure
    • Electrical Machine air-conditioned Platform

Bucket Elevator

Bucket Elevator
  • Designing and Selection of bucket sizes, Bucket Spacing for centrifugal discharge & high-speed elevators as per material characteristics.
  • Selection of Drive Head, Bottom Head Pulley and Chain or belt.
  • Design of inlet and outlet chute with supporting frame and Casing.
  • Drive Calculations, selection of Motor and Gearbox.
  • Design of rigid structure & take-up.


  • Selection of Appropriate Crusher for given application, size and Gradation of Feed, Material Characteristics, Surge or peak loads.
  • Selection of Optimum drive po.wer required for crushing application
  • Selection drive component and its mounting on structure.
  • Design of heavy reinforced structure for crusher through FEA.

Other Industries

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    Our understanding on technologies helps in reducing manufacturing costs, improving robustness in design.

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    We specialize in considering critical safety aspects during the design of static and mobile equipment.

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    We prioritize critical usage conditions, applications, and standards in our material handling equipment designs.

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    We work on Core Disciplines and follow an agile approach and add value in our engagements

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    We offer small form factor designs to multi-board system designs.

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    Services for PLCs, HMI, Motion Controllers, Servo Amplifiers, VFD and Plant automation is offered.

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    Services from compliance management, risk mitigation for medical device manufacturers to meet global market regulations

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    Virtual reality (VR), augmented reality (AR) and Mixed reality connect the virtual and physical worlds. They allow you to visually absorb information

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    Reach us for a comprehensive product/process documentation to different stakeholders​.

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    We engage with Global Captive Centre’s by addressing Talent Crunch in Electronics and Mechanical Engineering domains.

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iLenSys Technologies Pvt. Ltd.

MLA Colony, Road No: 12, Banjara Hills,
Hyderabad, Telangana 500 034
Phone: 040 – 66998246, 040 – 66998234
Email: info@ilensys.com