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Bulk Material Handling

INDUSTRIES

Bulk Material Handling System Construction

Design-build construction and complete installation of bulk material handling systems — conveying, storage, transfer, and reclaim infrastructure for grain, feed, fertilizer, and dry bulk industrial materials across North America.

Material Handling Capabilities

Moving Product Efficiently From Receive to Ship

Bulk material handling systems are the lifeblood of grain elevators, feed mills, biofuel plants, and agri-industrial facilities. A well-engineered handling system maximizes throughput, protects product quality, minimizes downtime, and reduces long-term operating cost. A poorly designed system becomes an operational bottleneck that limits your facility’s performance from day one. Todd & Sargent’s engineering team designs every handling system with a deep understanding of the material being moved, the equipment required to move it, and the operation it must serve.

Belt Conveyor Systems

Belt conveyors are the workhorses of bulk material handling. Our team designs and installs enclosed belt conveyors, open troughed conveyors, grasshopper conveyors, and ship/barge loading conveyors for grain, biomass, fertilizer, and other dry bulk materials. We size drives, specify idlers and pulleys, and design loading and discharge points for long service life and low maintenance.

Bucket Elevator Systems

Grain legs, industrial bucket elevators, and high-capacity belt-bucket elevator systems are central to grain elevator and processing facility design. Our structural engineers design the elevator towers that house these systems, while our millwright crew installs the mechanical components to exacting manufacturer tolerances
— ensuring smooth, efficient operation from day one.

Drag & Chain Conveyors

En-masse drag conveyors, paddle conveyors, and chain conveyors are used throughout grain and feed handling systems for gentle, enclosed product movement. We provide turnkey supply and installation of these systems as part of complete facility projects or standalone handling system contracts.

Pneumatic Conveying Systems

Dilute-phase and dense-phase pneumatic conveying systems move finely divided or granular materials through enclosed pipelines using air pressure or vacuum. Our engineering team designs pneumatic systems for feed ingredients, flour, specialty chemicals, and other materials where completely enclosed, dust-free conveying is required by process or regulatory requirements.

Transfer & Receiving Structures

Transfer towers, head houses, receiving pits, and loadout structures are the nodal points of bulk material handling systems. Our concrete and structural steel teams build these structures for decades of service, while our process engineers design the internal equipment arrangements to move material efficiently through every transition point in the system.

Storage & Reclaim Systems

Live storage bins, flat storage buildings, and pile storage with active reclaim systems are integral to bulk material handling networks. We design and build storage systems with reclaim conveyors, drag-out floors, sweep augers, and front-end loader reclaim tunnels tailored to your specific material properties and throughput requirements.

Handling Systems Designed for Long-Term Performance

A bulk material handling system is only as strong as its weakest link. Todd & Sargent’s system design approach evaluates every component — from receiving pit to ship loader — as part of an integrated network where each element must perform reliably for the whole system to operate efficiently.

We begin by characterizing your material — bulk density, angle of repose, particle size distribution, abrasiveness, moisture range, and cohesion characteristics. From there, our engineering team develops a system layout that balances capital cost, operating efficiency, and long-term maintainability — then designs every structural, mechanical, and civil component to support that system through decades of operation.

Every bulk material handling system Todd & Sargent designs includes a systematic review of NFPA 61 and 652 dust explosion requirements, OSHA conveyor guarding requirements, and state and local building code compliance.

System capacity modeling and throughput bottleneck analysis

Material flow simulation and equipment sizing calculations

Dust control and combustible dust explosion protection design

Structural design for conveyor galleries, trestles, and transfer towers

Electrical and process controls integration coordination

Maintenance access, housekeeping, and safety design

NFPA 61 and NFPA 652 compliance review and documentation

Conveyor guarding and OSHA compliance

Bulk Material Handling FAQs

What bulk materials does Todd & Sargent design handling systems for?

Our primary expertise is in agricultural bulk materials — corn, soybeans, wheat, sorghum, barley, oats, dried distillers grains, soybean meal, canola, and other grain commodities. We also design handling systems for feed ingredients, fertilizers, and industrial dry bulk materials with similar handling characteristics.

Yes. Our process engineering team designs complete system solutions from truck/rail/barge receiving through storage, processing, and product loadout. We evaluate every transfer point and equipment interface as part of an integrated system — not as individual pieces of equipment.

Yes. Todd & Sargent’s millwright crew self-performs the mechanical installation of belt conveyors, drag conveyors, bucket elevators, and related handling equipment as part of our design-build project delivery. This single-source responsibility for both design and installation eliminates the interface risk between equipment designer and installer.

Design a Handling System That Works

Let our engineering team develop a bulk material handling system that maximizes throughput, minimizes downtime, and serves your operation for decades.

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Mark Olesen

Mark Olesen

Chief Operating Officer

Mark Olesen is responsible for overseeing company operations, including developing and elevating our people, teams, and processes to take the best way T&S does things and engrain them into everything we do. He has over 45 years of commercial and industrial construction experience, serving in operations leadership and executive roles for over 30 years and as an advisor to construction contracting organizations since 2018. Mark has a bachelor’s degree in industrial construction management from Colorado State University. He has been an active member of Associated Builders and Contractors and Associated General Contractors throughout his career.

Karl Kratzke

Karl Kratzke

Director of Industrial Projects

As the Director of Industrial Projects at Todd & Sargent, Karl Kratzke leads the development and management of projects within the industrial processing sector. With nearly 20 years of experience, his expertise spans a wide range of markets, including oilseed, biofuels, biochemicals, liquid processing, food ingredients, feed ingredients, pharmaceuticals, and pet food. In addition to his background as a General Contractor, Karl spent nearly four years on the leadership team of a major food ingredient company, where he managed capital projects from concept to production, along with plant engineering and facility operations. A member of the Grain Elevator and Processing Society, he is dedicated to advancing industry standards and driving innovation. Karl holds a Bachelor’s degree in Construction Management from Minnesota State University and a Master’s degree in Integrated Food Systems Leadership from the University of Minnesota.

Jon Sargent CEO Todd & Sargent

Jon Sargent

CEO

Jon Sargent provides overall strategic and corporate direction to Todd & Sargent. In his role as CEO, he focuses on setting the company’s vision, leading the company’s leadership team, and ensuring the company lives its values every day. Jon is a member of the Grain Elevator and Processing Society (GEAPS), Construction Management Association, and former board member of Associated Builders & Contractors of Iowa. Jon graduated from the University of Iowa with a B.B.A. in Finance and from the University of Chicago with an M.B.A. in Economics. He is also a member of The Sargent Group, Inc. Board of Directors. Jon has been with Todd & Sargent since 2010.

Brian Watson

Brian Watson

Vice President – Project Management

Brian Watson is responsible for project management at Todd & Sargent, bringing consistent project delivery to our clients. He works closely with our project management teams and clients to ensure project quality, schedules, and budgets are met. Brian is a member of the Grain Elevator and Processing Society and International Association of Operative Millers. Brian graduated from Iowa State University with a degree in Construction Engineering and has been with Todd & Sargent since 2014.

Christie Mohlke

Christie Mohlke

Vice President – People

Christie Mohlke leads all HR functions at Todd & Sargent, such as culture, recruiting, training, compliance, employee onboarding and orientation, employee relations, benefits, and more. She has over 10 years of experience in human resources focusing on operations management. Christie graduated with a B.B.A. in Marketing from Austin Peay State University and a Master’s in Business Administration from Cumberland University. She is a member of the National Society of Human Resource Management and is designated as a Professional of Human Resources.

Lesley Whitten

Lesley Whitten

Director of Operations – Canada

Lesley Whitten oversees all aspects of our Canadian operations, from project management and engineering to field operations to ensure each facility meets client expectations. She has more than 15 years of experience in the construction industry, and she has worked on many new grain elevator builds, large scale elevator and facility upgrades, fertilizer facilities, and canola crushing plants while serving in roles from project coordinator up to project management manager. Lesley holds a CET (Certified Engineering Technologist) and PMP (Project Management Professional) accreditation.

James Bucher

James Bucher

Chief Financial Officer

James Bucher is responsible for Todd & Sargent’s finance, accounting, and information technology functions. He manages the T&S accounting team, banking and insurance relationships, and oversees the annual audits of the company’s financial statements, benefits plans, and insurance programs. James graduated from Iowa State University with a B.A. in Accounting and holds his Certified Public Accountant designation. James has been with Todd & Sargent since 2017.

Pat Taggart

Pat Taggart

Vice President – Field Operations

Pat Taggart is responsible for field operations at Todd & Sargent. His duties include overseeing safety, field construction teams, construction scheduling, and project quality assurance. He also oversees Todd & Sargent’s warehouse team. Pat graduated from Iowa State University with a B.S. in Agriculture Studies. Pat has been with Todd & Sargent since 1983.

Bryan Coussens

Bryan Coussens, P.E.

Vice President – Design & Engineering

Bryan Coussens is responsible for all aspects of Todd & Sargent’s design and engineering function. Bryan manages Todd & Sargent’s team of engineers, drafters, and designers to meet our clients’ complex engineering needs. He provides structural, process, and value engineering for projects in the grain, feed, flour, biofuels, and specialty industries. Bryan also reviews projects for code requirements and compliance. Bryan is a member of the American Concrete Institute and the American Institute of Steel Construction. He graduated from Iowa State University with a B.A. in Civil Engineering. Bryan has been with Todd & Sargent since 1996.

Scott Sylvester

Scott Sylvester

Vice President – Business Development

Scott Sylvester is responsible for developing and maintaining strong client and partner relationships as well as identifying new market opportunities at Todd & Sargent. He has over 20 years serving clients and partners in the Ag and Industrial construction markets. He is an active member with the Iowa Association of Business and Industry and past member of Food Processing Suppliers Association and Iowa Lean Consortium. Scott graduated from the University of Northern Iowa with a General Studies degree, with an emphasis on communications and psychology.

Alex Kerrigan

Alex Kerrigan

Vice President – Project Development

Alex Kerrigan is responsible for project development at Todd & Sargent, bringing ag and industrial projects from concept to reality. Alex works closely with each client’s team to develop successful facility designs and compile comprehensive and competitive cost estimates. Alex is a member of the American Feed Industry Association, Grain Elevator and Processing Society, International Association of Operative Millers, and National Grain and Feed Association. Alex graduated from the University of Notre Dame. Alex has been with Todd & Sargent since 2002.

Rori Bouchard

Rori Bouchard

President – Canada

Rori Bouchard leads our Canada team to fulfilling the company mission and vision and ensures our company lives its values every day. He has more than 15 years of industry experience, with specialized knowledge in all facets of the construction of ag-industrial facilities with experience as a project manager, business development director, and managing director, among other roles. Rori is a member of the Association of Professional Engineers & Geoscientists of Manitoba and Grain Elevator and Processing Society. He graduated from the University of Manitoba with a B.S. in Mechanical Engineering and a minor in Management.

Jon Sargent

Jon Sargent

President & CEO

Jon Sargent provides overall strategic and corporate direction to Todd & Sargent. In his role as President & CEO, he focuses on setting the company’s vision, leading the company’s leadership team, and ensuring the company lives its values every day. Jon is a member of the Grain Elevator and Processing Society (GEAPS), Construction Management Association, and former board member of Associated Builders & Contractors of Iowa. Jon graduated from the University of Iowa with a B.B.A. in Finance and from the University of Chicago with an M.B.A. in Economics. He is also a member of The Sargent Group, Inc. Board of Directors. Jon has been with Todd & Sargent since 2010.