Plant Reliability Solutions for
Cement Industry

Forecast equipment failures. Reduce unplanned downtime.
Improve plant productivity. Optimize maintenance strategies.

Online Monitoring & Diagnostics for Equipment in the Cement Industry
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With the Cement industry’s focus shifting from ‘Volume to Value’ and an ever-increasing demand for sustainable manufacturing, the need to optimize plant availability and reliability is urgent.
Ineffective maintenance strategies often cause sudden failures and lead to the unavailability of critical industrial assets. Such unplanned production downtime can directly translate into millions of dollars of revenue losses, and compromise the health and safety of the cement plant maintenance staff.
With a strategic shift to the Predictive Maintenance model pertinent reliability objectives can be achieved in Cement manufacturing.

Raw Material Handling
Stacker Reclaimer Crusher Feeder Vibrating Screen Belt Conveyor

Raw Mill Section
Vertical Roller Mill Classifier Raw Mill Fan Belt Conveyor Raw Mill Exhaust Fan

Pyro Section
Kiln Main Drive Girth Gear & Pinion PA Fan Preheater Fan Bag Filter Fan Kiln Feed Elevator Clinker Cooler Fan

Silo
Deep Pan Conveyor Belt Conveyor

Cement Mill
Mill Main Drive Bucket Elevator FD Fan ID Fan

Roller Press
Planetary Drive Movable Roller Fixed Roller

Packaging Plant
Bucket Elavator Deep Pan Conveyor Bag Filter Fan

Powerplant Boiler Feed Pump PA Fan SA Fan ID Fan CEP Pump Vacuum Pump Cooling Water Pump Demineralization Pump Gas Turbine Cooling Tower Fan

Cement production is among the most intense of all manufacturing procedures. The creation of Portland and Masonry cement involves chemicals like silicates, aluminates, and aluminoferrites, which can merge to generate a large amount of fine particles.

This can pose substantial challenges for the equipment used in production and handling. The demanding working conditions, coupled with elevated temperatures, lead to an accelerated degradation of rotating parts, posing a risk of early breakdown.
The operation and upkeep of assets in a cement facility pose significant challenges due to the following reasons:
  • The average machine age in a cement plant is at least 30-40 years.
  • Finding the right expertise to maintain them consistently is challenging.
  • Remote locations of cement plants make reactive action expensive and delayed.
  • Every machine – big or small – has the power to bring the whole process to a complete standstill.
Presently, the cement sector is on the brink of a digital revolution, driven by escalating demand, fierce competition, and increasingly rigorous regulations. The strain on the industry’s assets, processes, and workforce to perform at their peak is unprecedented. In this context, employing Predictive Diagnostics as a Service for your cement facility can aid in preventing machinery breakdowns and the consequent unexpected downtime, thereby enhancing the quality of the produced cement and the Overall Equipment Effectiveness (OEE) of the plants. This service not only enhances machine uptime and efficiency but also reduces expenditure on repairs and spare parts. Most crucially, it equips you with resilience and adaptability during uncertain times through remote monitoring and timely proactive maintenance when it’s most needed.
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Improving Operations & Reliability in the Cement Industry

Four out of five companies lack the data or ability to calculate downtime costs accurately. Digitalization can be a critical enabler of productivity and process improvements by identifying the top causes of downtime. A global Cement manufacturer increased total factory uptime by 1088 hours with plant reliability solutions.
Strengthen production levels, eliminate unplanned cement plant downtime, and make plant maintenance stress-free with AI-enabled Predictive Maintenance solutions designed for Cement Industry.
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Digital Reliability- Driving sustainability for next-gen cement plants

Four out of five companies lack the data or ability to calculate downtime costs accurately. Digitalization can be a critical enabler of productivity and process improvements by identifying the top causes of downtime. A global Cement manufacturer increased total factory uptime by 1088 hours with plant reliability solutions.
Strengthen production levels, eliminate unplanned cement plant downtime, and make plant maintenance stress-free with AI-enabled Predictive Maintenance solutions designed for Cement Industry.
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Enable Data-Driven Manufacturing

Access 360-degree view of plant process, equipment conditions, and real-time data to predict machine failures. Utilize data as a foundation to extract advanced analytics insights and accurately plan machine maintenance activities with minimal impact on production targets.
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Extend Life of Machinery

Reduce resource wastage through digitized equipment condition monitoring in cement plant, generating value throughout the intended machine life. Achieve sustainability goals and get the most out of plant assets with digital reliability and cloud-enabled solutions.
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Adopt Responsive Maintenance Approach

Employ responsive maintenance models to reduce critical incidents, prevent production outages, and enable better control of maintenance programs. Improve production quality and process compliance by ensuring optimum condition for every equipment.
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