Technology
Towards a smart world
Published
8 years agoon
By
admin
IT has been making radical changes in how we do things, and the cement industry is no exception. Condition monitoring of high-value assets is an age old practice, but the novelty brought in by IT, is on line condition monitoring even from remote places. DALOG from Germany has taken pioneering steps to propagate the idea.
To prevent breakdowns is good but the goal must be to avoid machine failures from the beginning. This has been the aim of the DALOG GmbH for almost two decades. Ever since their online condition monitoring systems helped to maximise the availability of machines by making precise analysis and supporting the plant team remotely with failure predictions, maintenance preparation support, and even advice for process improvement. Yet, the outcome on the production can only be assured by an interconnected monitoring solution that covers the full value chain of the cement production process.
Process correlated condition monitoring
Creating save islands in the plants by monitoring the most critical assets with acceleration and temperature sensors allows to predict failures on gears and bearings before they end in a catastrophic breakdown. A tooth failure on a gear can be detected before it breaks off and turns into a loose cannon within the gearbox. A bearing with upcoming pitting can be ordered in time. Statistical models even allow to predict the remaining lifetime of a machine component. In general, failures are detected at an early stage, which gives time to act and plan. Plants benefit from less unplanned stoppages and a minimisation of secondary damages.
The next logical goal is to increase the time between failures, by optimising operational stability. The torque measurement on rotating shafts has shown to precisely measure the real load on the machine and a high frequency measurement shows peaks not visible in the motor power. Consequently, it is a valuable tool to evaluate operational stability and to detect dangerous overloads on the machine. This is especially important for machines with a high dynamic process like vertical roller mills and roller presses, where operational instability can often be related to issues in the grinding elements or the process, like an improper feed. For a root cause analysis in the process, the online condition monitoring system needs to be able to communicate with the PLC to receive parameters like feed rate, pressures and motor power; sending alarms and trends to the DCS, helps to integrate the operators in the project, which gives them the necessary information to take appropriate measures to prevent machine failures or instabilities.
One of the big challenges for the cement industry towards a successful transition to the digital factory, will be the standardisation of communication protocols. OEM proprietary protocols dominate the cement plants and given that this situation will not change soon, the DALOG condition monitoring system supports most of the fieldbus protocols, to establish a bi-directional communication with the PLC. The key elements to prevent failure in the future are real load measurements with a torque sensor, the data exchange (process and condition) between the condition monitoring system and machine control, and the integration to the operator.
Online data acquisition for all machines
The industry has made great progress in the last years with its maintenance strategies. The FMEA (Failure Mode and Effects Analysis) today is a standard tool evaluate risks and thus even today many of the most critical machines, like mills and kilns, are equipped with an online condition monitoring system and respectively covered by the predictive maintenance strategy. Nevertheless, less complex and smaller equipment, like fans, conveyors, or bucket elevators, often fall through the net, besides its clear impact on the production. The maintenance strategy for those machines in today`s plants are either "run to breakdown", preventive, or condition based with temporal measurements on the equipment. They all have in common that the initial investment is very low, but the ongoing operational costs are soaring. The run to failure strategy bears a lot of risks and will cause unplanned stoppages and production loss.
Preventive maintenance reduces the risk, but relies solely on life-time estimations or manual inspections to schedule maintenance intervals. This either results in changing machine parts too early or too late, one ends in higher spare part investment, the other in production loss. Condition based maintenance intervals can be achieved by mobile measurements. Yet, the quality and reliability of an analysis with mobile equipment has a high variance. They are time consuming and must be carried out by trained personal that needs to fulfill a rigid schedule taking those measurements. Risks involve selecting a non-optimal measurement position, not considering different machine production situations at the time of the reading, or in the worst case, not taking the measurement after all. Trend analysis and process correlation is in the best case suboptimal.
The cement plant of the future will solely rely on a predictive and proactive maintenance strategy, which bases its decisions on data from online condition monitoring systems. The advantage lies on the hand: while reducing time consuming field work, the plant can count on more precise measurements and a higher data density, thus a higher reliability of their predictions and consequently a higher availability of the plant.
New challenges for maintenance
As the data density increases and analysis algorithms improve, what about the typical tasks for the maintenance team? While it is possible to measure the impacts of the tropical rain fall on the feed of a vertical roller mill in a cement plant in the Philippines, or to detect the effects of sand (silica) on the operational stability in a roller press in the Mid-West, it is yet a great task to integrate all the external influences into an algorithm that could replace the judgement of a trained expert. On the other hand, as reliability increases and field work decreases, more time and effort will be spent on performance optimisation and the collected data will build the foundation to plan, carry out and measure the outcomes of such initiatives. Experienced vibration analysis, maintenance, and process experts from DALOG, guide already today many plants to interpret the data and optimise their performance.
Online condition monitoring
How can online condition monitoring go even further and support a company-wide strategy? Wikipedia defines strategy as "a high-level plan to achieve one or more goals under conditions of uncertainty". It is clear how online condition monitoring continuously provides information to maintenance to eliminate uncertainty. But why stop there? The DALOG online condition monitoring solution acquires data in high resolution to evaluate machine condition, operational stability and process parameters that will help to evaluate the overall performance. The latest software generation DALOG Busy Bee calculates KPIs and statistics that are visualised in customisable dashboards. It is possible to display statistics about machine availability, energy consumption and operational stability, to name just a few. Surely, the access to the data is not limited locally to plant facilities. An encrypted connection to the cloud permits to access the data worldwide from a laptop, smartphone or tablet. This allows regional managers and headquarters to gain insight about the performance and condition of cement plants of a region, or country, thus any production strategy within the organisation will be exposed to less uncertainty.
A look back and the possibilities we have today
DALOG was founded in 1998. Back then, it was state-of-the-art to equip the monitoring system with a GSM module to dial up and establish a 9.6 kBit/s connection. Few people back then could have imagined that today most plants have access to the internet 1,00,000 times faster (1 Gbit/s). I would not dare to make a prediction for the technology we will have in 20 years, but I can say what is possible since today.
The DALOG Plant Protection Concept is a bottom up approach where on the lowest layer data is collected and stored on the cloud.
The massive amount of data is processed to be useful for different stakeholders within the same organisation. The maintenance team can work with precise failure analyses and can plan maintenance intervals based on machine condition and proactively work on increasing the time between machine failures.
The production team gains statistics and models for production planning. The plant manager can evaluate overall plant performance comfortably from his smartphone. In the end, online condition monitoring will build the foundation, for a seamless integration of data-driven decision making within the whole organisation.
Courtesy: DALOG, Diagnosesysteme GmbH, Muehlbachstr. 21
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Economy & Market
RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways
Published
1 day agoon
March 16, 2026By
admin
Roundtable discussions focus on innovation for safer highways.
Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.
Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.
Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.
RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.
Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.
Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.
The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.
From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.
Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.
Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.
Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.
The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.
Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.
The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.
Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.
Economy & Market
CTS Roundtable Charts Tech-Led Roadmap for Construction
Published
1 day agoon
March 16, 2026By
admin
CTS Roundtable Maps Technology Roadmap for Construction
Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.
Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.
A platform to move from discussion to deployment
Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.
Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.
Industry at a turning point
Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.
Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.
His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.
From BIM to AI, data to governance
A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.
Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.
Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.
The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.
Industrialised construction gains ground
The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.
Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.
Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.
Adoption remains the biggest hurdle
While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.
Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.
Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.
That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.
Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.
Beyond buzzwords
A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.
The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.
Setting the agenda for CTS 2026
By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.
More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.
As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.
The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.
Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.
Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.
Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.
Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.
A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.
Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.
About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.
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