Optimus Solutions

What Optimus Solutions does

Optimus Solutions, Inc. is a privately held process engineering consulting firm that specializes in rotary industrial equipment, including kilns, dryers, calciners, and ball mills, serving industrial operators across cement, mining, minerals, aggregates, chemicals, and other process industries in North America. The firm operates from a headquarters in Louisville, Kentucky, and runs a field-based delivery model in which engineering staff perform on-site surveys, tune-ups, and troubleshooting at customer plants. The company is incorporated in Kentucky, with a website copyright spanning 2018-2026, and is independently owned with no disclosed external investment or parent company. The leadership named in source materials includes Tom Zhang (Principal Engineer and Business Development).

Name

Optimus Solutions

Legal name

Optimus Solutions, Inc.

Website

https://optimusps.com

Company type

Private

Founded year

2018

Operating status

Operating

Headcount range

101–250 employees

Short description

Optimus Solutions is a process engineering consulting firm serving industrial operators of rotary kilns, dryers, and calciners across North America. It delivers alignment surveys, combustion services, advanced engineering analyses, and hardware distribution via direct field engagements.

Ownership category

akta.pro rank

Product category

Industrial Process Engineering Services

NAICS

Instruments and Related Products Manufacturing for Measuring, Displaying, and Controlling Industrial Process Variables (334513), Navigational, Measuring, Electromedical, and Control Instruments Manufacturing (33451)

SIC

Industrial Instruments For Measurement, Display, And Control (3823), Optical Instruments & Lenses (3827)

akta.pro industry

PRIMARYIMAIAMAF

Industrial Quality Inspection & Metrology (Machine Vision)

Industrials, Manufacturing & Construction/Industrial Services & Facility Operations/Industrial IoT (IIoT) & Smart Manufacturing

SECONDARYIMAGAFAB

Machine Vision & Optical Sensing (Cameras, 3D vision, LiDAR, illumination)

Industrials, Manufacturing & Construction/Electrical Equipment & Industrial Electronics/Sensors, Instrumentation & Measurement (Industrial sensing, metrology, test)

SECONDARYIMAHADAK

Metrology, Inspection & Machine Tool Accessories (CMMs, Probing, Gauging)

Industrials, Manufacturing & Construction/Industrial Machinery & Heavy Equipment/Machine Tools & Metalworking Equipment

Keywords

• Rotary kiln engineering
• Alignment surveys
• Combustion services
• Process engineering consulting
• Industrial equipment maintenance

Headquarters

HQ city

Norcross

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Services

Cost components

Personnel, Operations, Marketing or Sales, Technology or R&D, Supply Chain

Revenue model

1. Engineering Survey Services: On-site engineering surveys including DATscan (cold survey), Kiln Axis Survey (hot survey), and Custom Mechanical Measures. These precision engineering engagements are delivered as professional service engagements with written reports and engineering review sessions.
2. Combustion Equipment Parts: Sale of burner parts including flow meters, regulators, blocking valves, fuel control valves, and complete burner units sourced from various manufacturers. Also includes controls and instrumentation.
3. Hot Oil Heater Parts & Service: Replacement parts and field service for hot oil thermal heaters including burners, expansion tanks, and coils. Exclusive service provider for First Thermal Heaters™.
4. Burner Tune-Up & Maintenance Services: On-site combustion analysis, airflow analysis, and burner optimization services, typically delivered as a one-day site visit with written reports. Recommended annually for kiln and dryer operators.
5. Advanced Engineering Services: Load studies, FEA, 3D flighting studies, CFD, system sizing, and custom engineering measures delivered as specialized professional consulting engagements.
6. TomTom-Tools Distribution: Exclusive North American distributor of TomTom-Tools measurement equipment designed for large rotary equipment including kilns and dryers.

Go-to-market motion1 record

Distribution channels3 records

Marketing channels4 records

Core offering

Optimus Solutions provides process engineering consulting and field services for industrial rotary equipment (kilns, dryers, calciners, ball mills). The company delivers precision alignment surveys (DATscan® cold survey and Kiln Axis Survey / KAxS hot survey), combustion and burner services (tune-ups, troubleshooting, startup assistance, airflow studies), advanced engineering analysis (load studies, FEA, 3D flighting, CFD), and exclusive North American distribution of TomTom-Tools measurement instruments.

Product overview

Optimus Solutions is a process engineering company specializing in rotary equipment parts and technical services. The offering consists of three main service categories: Alignment Surveys (DATscan cold survey, Kiln Axis Survey, and Custom Mechanical Measures), Combustion Services (burner parts, tune-up, troubleshooting, startup assistance, airflow services, and SpraySafe lubrication products), and Advanced Engineering (load studies, FEA, 3D flighting studies, CFD, and custom services). The company also distributes TomTom-Tools as the exclusive North American distributor and serves as the exclusive service provider for First Thermal Hot Oil Heaters. A customer portal (Genius) is provided for client access. These products and services work together to provide comprehensive kiln and dryer engineering, from diagnostic surveys and measurement to combustion optimization and mechanical analysis.

Differentiator

Problem solved

Functional benefit

Brands

• SpraySafe™: An all-in-one lubrication cabinet designed to hold a 55 gallon drum of lubricant, pre-wired, pre-plumbed, and heated with custom spray lance and alarm system.
• DATscan®
• Kiln Axis Survey (KAxS)
• TomTom-Tools

Products and services

• DATscan (Cold Survey) A cold drum engineering survey performed when a rotary dryer is shut down, measuring system alignment with +/-0.040" accuracy using optical instrumentation and wireless measurement tools. Provides baseline measurements including system slope, base slope, tire/roller angles, and visual inspection data for industrial rotary equipment operators.
• Kiln Axis Survey (KAxS / Hot Survey) A comprehensive engineering survey for operating rotary kilns delivering real-time data on multi-pier alignment (horizontal/vertical), kiln shell ovality, tire creep, shell temperatures, and optional gear runout, tire wobble, and kiln crank measurements. Includes data-driven recommendations verified by Optimus engineering team.
• Custom Mechanical Measures Customized engineering survey with measurements designed to diagnose root causes of non-conventional problems in rotary equipment that fall outside standard KAxS or DATscan offerings.
• Burner Tune-Up Annual burner inspection and calibration service including combustion analysis, airflow analysis, PPM measurements, fuel train inspection, and optimization for rotary kilns, dryers, and hot oil heaters. Delivered as an on-site one-day visit with written reports.
• Combustion Troubleshooting Root cause investigation services for burner issues, instrumentation problems, process performance issues, fuel train issues, and pilot malfunctions in combustion systems serving industrial rotary equipment operators.
• Startup Assistance Post-installation or modification startup service for combustion systems including system inspection, burner pressure setting, control parameter configuration, and performance optimization (average duration approximately two days).
• Airflow Services Airflow studies using pitot tubes to determine airflow distribution, fan sizing for combustion and induced draft fans, and duct sizing based on pressure drop calculations for industrial combustion systems.
• Burner Parts Combustion system fuel train components including flow meters, regulators, blocking valves, fuel control valves, and complete burner units sourced from multiple manufacturers, sold to industrial plant operators.
• SpraySafe™ Lubrication Cabinet Trademarked all-in-one lubrication cabinet designed to hold a 55-gallon drum of lubricant, pre-wired, pre-plumbed, and heated with a custom spray lance and alarm system to prevent lubrication disruptions in rotary equipment operations.
• Hot Oil Thermal Heaters Service Exclusive service provider for First Thermal Heaters™ offering field service, replacement parts (burners, expansion tanks, coils), yearly inspections, audits, and parts for hot oil thermal heaters of any brand serving industrial process operators.
• Load Studies Engineering analysis determining force on tires, rollers, and shell for rotary kilns, dryers, ball mills, and processing equipment using beam analysis methodology that considers shell, tires, internals, refractory, and satellite coolers weights.
• Finite Element Analysis (FEA) Engineering analysis visualizing stress points and structural integrity of rotary units and components (tires, support rollers, shell sections) using FEA to diagnose failures such as cracks and fatigue in industrial rotary equipment.
• 3D Flighting Study

Quantifiable outcome

• DATscan accuracy of +/-0.040" — provides precision baseline measurements for maintenance decisions
• +1 more outcomes

Segments1 record

Ideal customer profiles2 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature5 records

Partnerships

One partnership is on record.

• TomTom-ToolscoreChannel Partner/ Reseller/ DistributorOptimus Solutions is the exclusive North American distributor of TomTom-Tools, a suite of measurement instruments designed specifically for large rotary equipment including kilns and dryers. The product line includes Kiln Axis Alignment System, Measuring Wheel, IDM Tool, Ovality Sensor, Kiln Shell Laser, Rotary Inclinometer, Rotation Trigger, and Mechanical Kiln Monitoring System. TomTom-Tools are designed to allow measurements while the unit remains running, a key differentiator for continuous operations.

Scale indicators3 records

Recent moves6 records

Expansion highlights4 records

Direct peers

• Industrial Kiln & Dryer Group (IKD): US-based rotary equipment training and consulting group. IKD delivers kiln/dryer operator training and is also an Optimus training partner, indicating direct overlap in serving the same rotary-equipment operator audience with adjacent advisory services.

Regional players

• TomTom-Tools: German manufacturer of precision measurement instruments specifically designed for rotary kilns and dryers. Optimus is their exclusive North American distributor; TomTom-Tools is the equipment counterpart whose underlying technology Optimus deploys and services across NA.

Broad incumbents

• FLSmidth: Global Danish engineering, equipment, and service supplier to cement and minerals industries including rotary kilns, pyroprocessing, and digital plant optimization — serving the same end customers as Optimus but at much larger scale and with much broader scope.
• KHD Humboldt Wedag: German supplier of cement plant technology including rotary kilns, clinker coolers, and grinding equipment plus aftermarket services. Targets the same cement and minerals end markets with equipment-level solutions versus Optimus' aftermarket measurement and combustion services.
• Thyssenkrupp Polysius (tkIS): Established German engineering brand specializing in cement plants, rotary kilns, and grinding systems. Comparable as a major incumbent in cement process technology that competes for the same operator relationships Optimus serves aftermarket.
• Metso: Global supplier of equipment, parts, and services for mining, aggregates, and minerals processing, including rotary equipment used in cement and minerals plants. Comparable as a broad incumbent serving the same industrial operator customers through a much larger aftermarket and service network.
• Hexagon Manufacturing Intelligence: Global industrial metrology and machine vision software/equipment company covering portable metrology, 3D measurement, and industrial quality inspection. Comparable as an enterprise-grade industrial measurement technology provider and adjacent competitor for advanced inspection work.
• Carl Zeiss Industrial Metrology: Zeiss's industrial metrology business supplies coordinate measuring machines, optical systems, CT, and 3D scanning for precision industrial inspection. Comparable on precision metrology expertise, though its primary end markets are discrete manufacturing rather than process industries.

Emerging players

• Renishaw: UK-based precision measurement and calibration company with industrial probing, laser, and encoder technologies used in machine tools and manufacturing quality inspection. Comparable on the measurement/precision-instrumentation axis that Optimus relies on for alignment surveys.

Others

• Keyence: Global supplier of industrial sensors, machine vision systems, and measurement instruments. Comparable on the optical sensing/measurement instrumentation technology stack that Optimus uses for rotary equipment surveys, though Keyence is a broad component supplier rather than a service competitor.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat4 records

Key risks5 records

Key highlights6 records

Customer concentration

• Xx.com/optimusprocess
• Facebookfacebook.com/optimusps
• LinkedInlinkedin.com/company/optimus-solutions

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Optimus Solutions