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Cement Plant Automation

Unlock Your Full Potential with Connected Processes and Efficient Solutions
Cement plant in operation in the evening
Cement Plant Automation
Unlock Your Full Potential with Connected Processes and Efficient Solutions
Cement

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 ourDigital 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

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18-25%

Reduced maintenance costs

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5-15%

Increased asset availability

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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.

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
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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
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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.

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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
Rotary kiln in cement plant at night
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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How Have We Helped Businesses Like Yours?

Ash Grove Cement Improves Reliability
Ash Grove Cement Ball Mill interior shot
Case Study
Ash Grove Cement Improves Reliability

Rockwell Automation solution provides cement manufacturer with initial savings of $250,000 and over 90 percent uptime.

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Vulcan Materials Company
Open pit cement site located at the Vulcan mine complex
Case Study
Vulcan Materials Company

The Cement Grinding Control Application from Rockwell Automation assists the leading cement producer in achieving significant gains through automated control.

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Manufacturing Intelligence Increases OEE Accuracy
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Case Study
Manufacturing Intelligence Increases OEE Accuracy

Manufacturing intelligence increases accuracy of OEE data for a cement manufacturer by providing automatic data collection and real-time reporting.

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Cement Plant Cuts Emissions by 2%
Two large storage silos next to four smaller storage silos at cement plant
Case Study
Cement Plant Cuts Emissions by 2%

Energy usage can account for 25-35% of the total cost of production. See how we helped a top cement company improve their kiln power consumption savings by 2% and expand their sustainability initiatives.

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Learn More About Our Products and Solutions

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Learn More About Our Delivery and Service Capabilities

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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.

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