Cement Plant
The cement industry demands innovative solutions to navigate the challenges of monitoring and maintaining equipment in harsh, dusty environments.
With critical assets like kilns, roller presses, and gearboxes operating under extreme conditions, the need for precise condition monitoring, early fault detection, and predictive maintenance is more crucial than ever to prevent downtime in cement plants.
Trusted by leaders like Lafarge and JK Cement, our predictive maintenance platform helps reduce unplanned downtime, remotely monitor equipment and optimize asset performance!
Trusted By Your Peers
Cement Industry Challenges
Complex Equipment
Cement plants have a variety of complex machinery, such as kilns, mills, crushers, and conveyors. Monitoring the condition of diverse and intricate equipment poses a challenge in terms of sensor placement, data collection, and analysis.
Dusty Environment
Operating in a dusty environment poses a challenge to machinery reliability. Robust solutions are imperative to combat the adverse effects of dust on equipment, ensuring optimal performance and longevity.
Limited Accessibility
Some critical equipment in cement plants may be located in confined spaces or at heights, making it difficult to monitor their health & performance.
How We Help Cement Plants Reduce Downtime
Robust Hardware with IP68 Rating​
Our solution incorporates robust IoT hardware designed to thrive in dusty environments commonly found in cement manufacturing plants. Certified with IP68, this robust hardware ensures resistance against dust ingress, guaranteeing reliable data collection and anomaly detection.
Customized AI-Based Platform for Cement Industry
The AI-based health analytics platform is specifically designed to cater to the unique demands of the cement industry. The platform’s customization ensures that it addresses the specific challenges and operational nuances of cement manufacturing plants.
Remote Monitoring for Increased Accessibility
We bring the power of Remote Monitoring with IoT & AI to the forefront, eliminating the need for human intervention in monitoring. This technology ensures continuous condition monitoring, providing real-time insights into the health and performance of your machinery, even in remote locations.
Accurate Remaining Useful Life (RUL) Predictions
With with our accurate Remaining Useful Life (RUL) predictions, our AI algorithms analyze historical data, equipment conditions, and performance trends to forecast the remaining lifespan of critical components.
Case Study: $500,000 Planetary Gearbox Failure Prevented at Leading Cement Manufacturer
A global leader in white cement manufacturing successfully prevented a critical gearbox failure using advanced condition monitoring.
Challenge:
Monitoring the Roller Press posed difficulties. Traditional methods failed to provide timely alerts for issues in the Planetary Gearbox and Journal Bearings.
Solution:
MachineDoctor 6-in-1 wireless sensors were deployed across all Roller Press bearing points. These sensors transmitted real-time data, with alerts notifying the team of early fault indicators.
Key Findings:
- Gear Fault & Lubrication Issues: Oil analysis revealed excessive moisture (>20,000 ppm vs. normal <500 ppm).
- Wear Particles: Elevated levels of cutting wear particles indicated abnormal machine wear.
- Action Taken: Gearbox oil was replaced during recent preventive maintenance.
Impact:
Early detection and AI-driven monitoring enabled proactive maintenance, preventing a $500,000 planetary gearbox failure and full rebuild.
Applications
Roller Press
Vertical Rolling Mill
Ball Mills
Bucket Conveyor
See it Work For You
Our cutting-edge predictive maintenance solutions are tailored to address the unique challenges faced in cement plants.
See how we seamlessly integrate with your process and help you eliminate unplanned downtime in your cement plants, reduce carbon emissions and improve your overall operational efficiency.