The typical processes in a cement plant are :

  • Extractors are used for Quarrying.
  • Crushers are used for crushing huge rocks into coarse raw material.
  • Blenders and Mixers are used to mix the ingredients in correct proportion.
  • Grinders mix the ingredients well to be heated in the rotary kiln.
  • The heating and cooling is carried in rotary kiln.
  • Finally, the cement is packed and dispatched using conveyor belts or transportation vehicles.

Equipment are monitored because

01. Equipments are over-maintained for higher productivity.

02. Equipment operates in harsh environment.

03. Bearings are replaced frequently to ensure equipment is in operations.

04. Expensive repair and replacement costs.

05. Ensure workforce safety and avoid accidents.

Typical Issues in Cement Plant

  • Loosening of nuts, bolts, springs, plates, spring rods, flywheel, bearings, shaft, coupling housing, hammer rotor
  • Motor failure, Conveyor belt, Breakage, bearing failure, stretching rod breakage, breakage of separator blade
  • Fan bearing breakage, fan unbalance
  • Gear knocking, gear tooth wear, gear deformation, gear spitting and spalling
  • Disc liner shift
  • Rolling mill cracks, tubing failure, pump failure, spoke breakage
  • Grate plate breakage
  • Axle spindle breakage, crusher bearings failure, slip tape breakage

How can Predictive Maintenance help Cement Plant?

  • Vibration reading of equipment can be collected.
  • On the basis of real-time triaxial vibrations, a trend can be obtained.
  • An insight can be generated which can be considered during weekly or scheduled maintenance work. Further analysis of the insights can speedup decision-making.
  • If any abnormality is detected, it can be sent to Maintenance team in the form of SMS and emails.
  • A timely remedial measure can be implemented to prevent breakdown, avoid production loss and ensure safety at work.
  • Predictive Maintenance can be accordingly scheduled. Corrective measures like Centrifuging, oil top up, oil replacement, bearing/gearbox inspection can be carried.

Predictive Maintenance for Cement plant equipment that’s used for grinding crushing, material transport systems, ball and roller mills, and material separators include:

  • Air Compressors
  • Belt drives or conveyors
  • Fans
  • Blowers
  • Kiln Rollers
  • Motor Bearings
  • Vertical and Horizontal Mills
  • Hammer Mills

Monitoring vibration energy, acoustics, and temperature helps to understand health condition of equipment.


We worked carefully with all our equipment that helped us for our living. We maintained them as and when required but still faced production losses and high downtime. Thank you Infinite Uptime for installing the IDE, to monitor gearboxes, motors, bearings and other critical mechanical rotating parts at real-time. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Sajo Paul - TVS Motors

Thanks to Infinite Uptime for providing insights into our critical equipment. The plug and play real time monitoring IOT 4.0 solution, avoided unexpected breakdowns and detected large savings capabilities. We are so happy, we could save our maintenance cost, spares, wear and tear, and the million dollar life of the operator.

Mr. Bhide / Mokashi, - Bharat Forge

We installed the IDE on our helical gearbox to get a deeper understanding of the root causes of its failures and prevented them becoming catastrophic. Outstanding product and people make Infinite Uptime an awesome part of the predictive maintenance.

Mr. Shashikant Bhujbal - Tata Metaliks

Thank You very much to everyone for installing the IU devices, integrating them with PLC in optimal time. We are now able to have an insight into tool life monitoring and can schedule predictive maintenance for the machines.
We look forward to continue work with you. We appreciate your dedicated time and efforts invested to achieve our goals.

Mr. Rahul Nalawade - Hirschvogel Components India Ltd.

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