Cement Plant Automation

Unlock Your Full Potential with Connected Processes and Efficient Cement Plant Automation Solutions

Cement plant in operation in the evening

Enhance Your Processes with Automation for the Cement Industry

In today's competitive marketplace, companies like yours must continue to innovate to improve productivity, increase revenue and differentiate their products. This must be done while navigating the significant challenges of globalization and increasingly stringent environmental regulations.

Our team of knowledgeable professionals combined with our scalable control and information technology can help you connect your operations and realize the wide-reaching benefits of digital transformation.

Create Smarter Efficiency with Digital Innovation

When prioritizing digital transformation outcomes, operational efficiency tops the list of both short-term and long-term goals. Cement companies often lack a unified strategy for digital investments due to legacy equipment and fragmented operations.

Innovative and data-ready technologies are needed to improve plant utilization, optimize processes, and reduce energy consumption. No matter where you are in your roadmap, we can help you take the next step in your digital transformation journey. Break the siloes with solutions that deliver business growth, drive productivity and decrease risk.

Learn more about our Digital Transformation Solutions and Digital Transformation Strategies.

Opportunities in a Volatile Environment

Arial image of a cement plant in the day time with blues skies n the desert

Market Study

Opportunities in a Volatile Environment

Overcome your business challenges and reshape your operations with Digital Transformation initiatives. Discover what areas top cement companies are targeting in their effort.

View Our Results

Where are Cement Industry Leaders in Their Digital Transformation Journey?

60%

Cement Plants have not completed digital transformation initiatives

2 out of 3

Users struggle to integrate data across systems

36%

Employees lack required skills for digital transformation technologies

Unleash the Power of Digital Transformation with Cement Plant Automation

18-25%

Reduced maintenance costs

5-15%

Increased asset availability

Outline of person wearing a hardhat standing in front of a factory

57%

Higher employee productivity

Extract Value at Every Stage of Cement Production

With a changing world and industry, your operations need to be agile. Remaining stagnant is no longer an option. How can you overcome these challenges?

Focusing your efforts on effective change can help grow the industry while remaining productive and profitable. Having a scalable, flexible and easy to integrate solution will help you increase productivity, lower costs, and reduce energy consumption all while taking a proactive approach to cybersecurity.

The Connected Cement Plant

Large cement plant arial view with smoking towers

Brochure

The Connected Cement Plant

Learn how you can improve operational efficiencies, reduce safety risks, and drive better decision-making with this end-to-end systems integration.

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Video

The Connected Cement Plant Video

Enable quarry-to-packing visibility and data-driven decision-making with integrated systems and scalable analytics.

What is Cement Plant Automation?

Cement plant automation refers to the process of using programable technology, including artificial intelligence (AI) and other smart manufacturing technologies to improve the efficiency, sustainability, and cost-effectiveness of cement production.

Benefits of Cement Plant Automation

Cement manufacturing is a complex and energy-intensive process. It involves many steps, including mining, crushing, mixing, and heating raw materials. Cement plant automation enables cement production processes to be carried out more efficiently, enabling cement manufacturers to improve energy efficiency, reduce emissions, and ensure the quality of the produced cement. It also enables cement manufacturers to cut down on wasted resources in the production process.

Key benefits of cement plant automation include:

More efficient plant operations
Reduced wasted raw materials
More robust system integrations
Improved agility to meet fluctuating supply and demand

Which Cement Manufacturing Processes Can Be Automated?

Cement plant automation can bolster nearly every step of the cement manufacturing process, from managing the supply of raw materials to the delivery of the finished product. Some processes unique to the cement manufacturing industry that can be automated include:

Raw material transfer
Bucket elevator automation
Cement grinding
Cement finishing

Interact with the Connected Cement Plant

Model Predictive Control can reduce energy cost, increase throughput, and maximize productivity. Discover how MPC can benefit your cement site with this interactive tool.

Explore the Tool

Process Solutions to Meet Cement Needs

Two workers onsite at a cement production plant walking towards an area with heaps of raw materials that includes sand and soil

Brochure

Process Solutions to Meet Cement Needs

Help achieve your production goals in a smart way. This standard approach to process control reduces engineering risks and is easier to operate, maintain and modify.

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Make Better Decisions with the Connected Cement Plant

Global cement demand is set to grow by up to 23% in the next 30 years. With this growth, knowledge-driven operations, a connected workforce, and operational efficiency are key to setting yourself up to meet this demand on-time and with the highest-quality product.

Take a modern approach to process solutions that will benefit each area of your cement plant. The PlantPAx® distributed control system (DCS) is a plant-wide, scalable, secure and information-enabled process solution.

Explore Our PlantPAx DCS Solutions

Achieve Peak Performance with Model Predictive Control and Analytics

New challenges in the cement industry are on the rise and producers must do more with less to keep up. Most companies have some process control system in place, but it often doesn't deliver the necessary processes stability and plant performance to meet expectations.

Add an extra layer of intelligence to your control system with our Pavilion8® Model Predictive Control (MPC) solution that helps you to achieve performance, reducing product variability while saving energy and reducing emissions in your cement plant.

Learn How Pavilion8 MPC Can Help Your Business

Model Predictive Control for the Cement Industry

Ash Grove Cement Conveyor System outdoor shot with 4 conveyors

eBook

Model Predictive Control for the Cement Industry

Maximum profitability is achieved by operating a process as close to its constraints as possible while maintaining an appropriate margin of safety. MPC optimizes the process by making predictions about future plant outputs responding to changes in the process input variables and disturbances.

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Video

Achieve Peak Cement Process Performance

Our cement MPC solutions have helped major producers reduce variable costs, enhance product quality and production rate, and achieve environmental compliance.

MPC is a simple, yet powerful technology that can integrate into your current control system to optimize your plant. We dive into what’s possible with MPC in our video.

Process Optimization Technologies for the Connected Cement Plant

Cement plant factory manufacturing have clinker cooler and other plant at sunset.

Article

Process Optimization Technologies for the Connected Cement Plant

This World Cement article highlights how Rockwell Automation helped a Texas cement plant experience increased production, stability, energy savings and quality benefits through MPC technology in its dry kiln automation project.

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Process Optimization Solutions by Area

Article

Process Optimization Solutions by Area

Dive into MPC solutions by area in this International Cement Review article highlighting Rockwell Automation MPC capabilities in cement.

Improve your Cement Plant Processes

Are you looking to:

Increase overall operational efficiency?
Reduce product and process variability?
Improve sustainability practices?
Increase productivity with better data?
Lower energy cost per ton?

Our Process Optimization Model Predictive Control (MPC) application can be applied to any process area in cement production.

Lean More About Process Optimization and MPC

Cement Finish Mill Application

Ball big industrial ball mill used for cement production

Technical Data

Cement Finish Mill Application

Our Model Predictive Control (MPC) application provides control and optimization of the crushing or grinding cement finish mill processes through patented, industry-leading technology.

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Pyroprocessing or Drying Application

Technical Data

Pyroprocessing or Drying Application

Our Model Predictive Control (MPC) application provides control and optimization of the pyroprocessing or drying processes through patented, industry-leading technology.

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Ready to talk to a Rockwell Automation consultant?

We offer industry expertise to help design, implement and support your automation investment.