Technology
Innovation at work
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7 years agoon
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adminInnovation is driving advancement of technologies and growth of the cement packaging segment globally. India must be able to take part and reap benefits from them.
While innovation is changing the way every work is done in every field of activity, cement packaging cannot be too different. Though there is hardly any change in the material consumed for manufacturing cement packaging, the new technologies and processes are making them high on productivity, safer, quicker to fill, load and re-load, leak-proof and amenable to automation, when compared to yester years when it was dangerous, hazardous and labour-intensive.
Bags are a common way of distribution in the industry, accounting for about 60 per cent of the product shipped to consumers/users. This also holds true for other developing countries, according to industry sources, which put the figure at 45 per cent on an average. Bulk packaging though is yet to catch up on a large scale in India, it is being patronised by some major cement manufacturers and bulk consumers.
Though there are several manufacturers of cement packaging bags in the country, most of the highly advanced automated machinery and systems are being imported from countries like Germany, Italy, Switzerland, the US, Taiwan, etc.
Innovation has been the key for sustained growth of global players like Windm?ller & H?lscher during the recent years, particularly when it has introduced hot air to seal the moisture-proof sacks that used to be closed with adhesives earlier, thereby reducing production costs and technical process limitations. Another global player, FLSmidth offers complete automation solutions by integrating various product types with that of fully automated packing plants, automating even loading and unloading activities.
Packing plants have not only become part of cement production lines, but also grinding stations or cement terminals. A single packing line produces up to 15 to 50 million bags per year based on the material used and the process adopted. That way, packing plants have evolved into complex, fully automated operations, driven by innovation in the recent years.Options
There are three options for cements sacks: Paper, woven and film. "Paper sacks are a comparatively cost-effective form of packaging made from a renewable source," says spokesperson of Windm?ller & H?lscher, which claims to be the market leader in the field of paper sack systems, with over 90 per cent share globally.
Woven polypropylene (PP)/plastic sacks are very lightweight and tear-resistant, which is particularly useful if the sacks are to be used in tougher environments. So, many Indian companies have embraced the option till the regulatory intervention, citing higher loss of cement in wrong handling. But they face a challenge – necessary deaeration of product.
A natural side effect of packing cementitious material into a polypropylene bag is trapped air. In order to make PP packaging a viable option for cement, this air needed to be managed back out of the process to achieve a uniform and stable
pack, which is a crucial ingredient for efficient palletisation. Achieving this, while maintaining the intended waterproof credentials of polypropylene and maintaining process speed is no mean task. However, this has been enabled by the latest technologies.
Film valve sacks, on the other hand, provide excellent moisture protection, and advertising on them is more effective as they hold print well, a factor which is key, particularly in the field of premium packaging.
"Valve sacks have the important benefit of being able to be filled on nozzle packers, which ensure a high filling output. Valve sack concepts are available in all three major materials (paper, pp-woven, PE-film). Important factors regarding filling speed and automated handling are deaeration performance and form stability," says W&H.
Packaging in cement production has to fulfil multiple needs like moisture protection, extended shelf-life, clean appearance and good handling, says W&H, while explaining the prerequisites for a cement bag. "Better stackability, pilfer-resistance, anti-counterfeit solution and better aesthetics are some of the reasons why the hot air sealed woven sacks have been preferred in the Indian market," added the W&H spokesperson. Besides, less flying of packaged product also helps cement users save cost. These benefits also help cement companies create a better brand image in the market-domestic or export.Store appearance
Look and feel of packaging, which was till recently confined to consumer goods packaging, is becoming an important parameter while selecting the medium of packaging even for the cement industry. Their importance is gaining prominence when it comes to product placement and communication to the end-customer, particularly about the sustainability angle of the product and/or its special strengths and features. As such, sacks need to present all marketing messages in an attractive way.
"Currently additional packaging features like carrying handle or easy opening feel an increasing market demand as those features present an added value regarding sack handling for the end-user," says W&H.
W&H is also seeing acceptance in India of high-end Biaxially-Oriented Polypropylene (BOPP) laminated hot air sealed block bottom bags, which are much more expensive than the conventional sewn bags, and are amenable for printing very high quality photographic images. New automatic range
Automation is catching up with packaging processes of cement industry, of late. The technique of making an apparatus, a process, or a system operate automatically as it is described is being opted for by the industry for taking advantage of its well-known attributes – increased productivity, more efficient use of materials, better product quality, improved safety and reduced factory lead times. The packaging automation has extended to loading of closed top and open top trucks or containers by now.
"In India, hot air sealed block bottom bags are the most used for high automation production. The benefit for bag producers is lower manpower requirement for producing as these bags are produced with high speeds and advance automation," says the W&H spokesperson.
AD PROTEX valve bags produced on CONVERTEX platform by W&H ideally combine minimum raw material usage, adhesive-free sack production and unequalled functionality of their box-shaped design. As a result, they are made in a particularly economical way, but can also be filled and palletized similarly as the conventional pasted valve bags. "Our new production line for cement valve packaging ensures the production of paper sacks which fulfil the requirements for automated high speed filling," the company said.
Packaging for dry powdered materials like cement has changed little in the last 40 years leaving the end user to cope with the problems associated with the industry standard paper valve sack. As a result problems such as dust, spillage and a relatively high wastage return rate caused by the ingress of water brought about by poor storage conditions have largely remained unchallenged.
However, domestic packaging manufacturer, Arodo has introduced it brand of vacuum bagging system that produces fully deaerated plastic packs that don’t feature perforations of any kind, addressing the concerns of cement manufacturers and their customers. It is projected as a waterproof and tamper-proof cement pack.
"The absence of perforations allows each individual pack to be stored or placed in the most arduous of weather conditions without risk of spoiling the product through water ingress," says Vikas Marwaha, Director, Arodo India Pvt Ltd. These packs have been placed outside and completely underwater for weeks before retrieving and using the product as if it had been freshly packed, Marwaha claims.
Windm?ller & H?lscher has developed CONVERTEX, which heat seals woven PP cross bottom bags and thus eliminates the need of glue for this type of bags. "During the last 10 years the output of the bottomer was more than doubled: from 60 bags per minute to 140 in the last model. This speed represents the technological leadership in this type of equipment," W&H said, stating that today, CONVERTEX forms the backbone of its extensive portfolio of the woven PP business.
High-quality PP tapes with tenacity up to 7 g/den and indexed micro-perforation provide the technological tools to be able to produce e.g. cement bags with a weight of 65 grams instead of the current global market standard of 80 grams. Drop tests with the LS Bags are done – with the result that LS bags easily excel conventional bags, W&H claims.
The AD proFilm MP sack, launched in 2015, is unusual in the sense that it uses hot air to seal the sacks. This means that it does not require adhesives, which can be the source of significant production costs and technical process limitations. It is manufactured on the AD PLASTIC 2 valve bottomer.
When the company was developing the new AD proFilm MP film valve sack, it chose to focus on two key factors: high moisture protection (MP = moisture-proof), and extending the product’s shelf life. It achieved these through the use of its innovative Breathing Chamber Technology – a ventilation chamber along the longitudinal seam of the sack. "This technology means that effective ventilation and high moisture protection are no longer mutually exclusive", explains Uwe K?hn, Head of Processing Products at W&H.
In a presentation made on June 21, 2017, Francesco Ferrandico, President-FLSmidth Ventomatic Cement Packaging said that the company’s automation systems range extends beyond filling of sacks to loading into trucks – open or closed. "FLSmidth Ventomatic provides the key product types and integrates them for fully automated packing plants," Ferrandico said while explaining about different packaging processes that include electronic rotary and inline packers; empty bag applicators; palletizing systems; loaders for closed trucks/containers; and loaders for open top trucks.
FLSmidth claims that its loaders for closed trucks/containers were the first full automatic pallet loading system in the market. Truck/container loaders significantly increase safety level and productivity and they do not use forklifts and relevant operators, it said. Its electronic rotary and inline packer’s equipment for filling bulk cement from silos into bags have an output from 60 tons/h up to 250 tons/h.
Depending on level of automation, packing plants consist of 2 – 8 packing lines, and at full automation, reduces required manpower per shift from 12 to 2 when going from complete manual to automation packing, but with the same output, FLSmidth added.Cementing growth
W&H has seen a huge growth in consumption of hot air sealed woven sacks in Indian market with several plants running already and more on order. It has also seen a trend in the market of use of high-end Biaxially-Oriented Polypropylene (BOPP) laminated hot air sealed Block Bottom bags. "These bags are much more expensive than the conventional sewn bags, but are finding good acceptance in the Indian market. These bags can be printed with very high quality photographic images," W&H spokesperson said. We also expect increase in consumption of multiwall paper bags in the Indian market. The reasons are very interesting, innovations like high strength paper and water soluble paper done by paper industries.
As packaging industry’s growth is tied to the Indian economy and demand for cement and cement products, growth in these two elements are of critical importance for sustainability and growth of packaging industry in the country. Though the current trends in cement demand do not augur well for the packaging industry, the Union Budget released recently have some good news to bask under.
During the first eight months of FY2018 (2017-18), cement production witnessed a marginal growth of 0.6 per cent at 190.0 million MT compared to 188.8 million MT during the same period the previous year, leading rating agency ICRA said, citing various factors like weak real-estate activity, sand shortage and issues related to implementation of GST as reasons. Based on the current trend, it projected that cement demand is likely to report a modest demand growth of around 2 percent in FY2018.
In a pre-budget (January 31, 2018) analysis, Sabyasachi Majumdar, Senior Vice President & Group Head, ICRA Ratings, said "Going forward, the demand growth is likely to be driven by a pick-up in the housing segment – primarily affordable and rural housing, and infrastructure segment – primarily road and irrigation projects. However, new project announcements from the private sector continue to remain weak and revival of public-private partnership is crucial to improve the pace of infrastructure development."
"ICRA expects the capacity overhang and moderate demand growth to continue to keep the industry’s capacity utilisation level between 60-65 per cent over the medium term," Majumdar added.
However, the Union Budget 2018-19 released on February 1, 2018, has some good news for the cement industry. The move to boost the capital outlay of Pradhan Mantri Awas Yojana (housing scheme) -Urban (PMAY-U) five-fold to Rs 31,500 crore, will aid some recovery in the otherwise muted urban-housing demand, which accounts for 30 per cent of cement demand, said leading rating firm, CRISIL in a post-budget report. Besides, increase in outlays for the Ministry of Road Transport and Highways (MoRTH) and Railways by 11 per and 22 per cent respectively are expected to impact cement demand positively.
However, CRISIL had added a word of caution, when it said, "Healthy budget outlay for cement-intensive infrastructure segments like roadways, irrigation and railways should cement growth (infrastructure share estimated at 20 per cent). However, achievement of budgeted outlay to be key monitorable as some shortfall was observed in the previous fiscal."
There is a marginal negative stroke for the sector from the budget in the form of social welfare surcharge of 10 per cent on customs duty, which replaces the earlier 3 per cent education cess on custom duty of all imports. This will particularly affect the advanced packaging equipment imports.Looking ahead
Innovations are driving advancement of technologies and growth of the cement packaging segment globally over the recent years. India being one of the major producers of cement has to make inroads into the top echelons of the sector by increasing spending on research and development and entering into joint ventures with major global manufacturers to lower our import dependency in the long run.
Major cement manufacturers like UltraTech Cement, ACC, India Cement and Ambuja have to take the lead in this initiative. This is an imperative when all the major manufacturers have to take advantage of latest technologies and improve their global competitiveness. Full automation may come in handy in this regard by boosting productivity and quality. Reduction of manpower may not be as important for India as it is for many other countries. Labour being cheaper in the country, the companies have to weigh the social impact of full automation in comparison with social benefit of utilising the cheap manpower, if other parameters like quality and productivity are not affected.
Adoption of advanced technologies also means guarding against health hazards for employees and stakeholders, which will lead to attraction and retention of talent, a critical resource for success of any business. It will also lead to optimisation of costs and leads to higher competitiveness, which are essential for the prosperity of companies and the country.– BS SRINIVASALU REDDY
Factors to be considered for best packaging
The factors one should consider while searching for the best packaging production are:
- Sack geometry
- Sack converting
- Sack design
- Appearance
- Stack design
Each aspect can be more or less important depending on the region and market the customer is looking for. Furthermore, different applications, availability of the respective materials, or even regional differences, sometimes with historical root causes may influence the decision. The supplier must be able to provide machines for the production of each sack type and after installation service.
Windm?ller & H?lscherCritical success factors in India
The following are the critical success factors (CSFs) that determine the future of a company or business, particularly for a player in the packaging equipment industry in India:
- Technology
- Price
- Delivery
- Performance standards
- Cost of equipment, and
- Low running cost
- Possible upgrades to the product and
- Aftersales/installation service
- Compiled from different sources
Growth through productivity: FLSmidth CARICATECHTM automatic truck loader
- Innovative development for loading all type of bags on all kind of trucks
- Bag layers are picked up by a fork with a special roller way (no vacuum system required) while maintaining the traditional loading from the top Addresses trend of productivity improvements through automation in developing markets
- CARICATECHTM replaces existing loading equipment without major process changes or rebuilds – targeting upgrades of existing packing lines
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By integrating advanced technologies like IoT and AI, cement plants are transforming into highly efficient and interconnected systems. ICR explores how these innovations enable real-time monitoring and predictive maintenance, significantly reducing downtime and operational costs.
The cement industry, traditionally known for its reliance on heavy machinery and manual processes, is undergoing a significant digital transformation. This shift is driven by advancements in technology that promise to enhance efficiency, reduce costs, and improve overall production quality. Key trends include the adoption of the Internet of Things (IoT), which enables real-time monitoring and control of production processes through interconnected devices. Artificial Intelligence (AI) and Machine Learning (ML) are being utilised to optimise operations, predict maintenance needs, and minimise downtime by analysing vast amounts of data. Additionally, the integration of Big Data analytics allows for more informed decision-making by providing insights into production trends and potential areas for improvement.
“One of the key advantages of integrating data across our systems is the ability to have a more transparent, agile, and integrated supply and logistics chain. With the implementation of Oracle Logistics Management Solution, we have been able to overcome challenges related to consignment locations and truck movements, providing real-time visibility into our operations. This has also led to operational efficiency improvements and the ability to predict consignment delivery times, which we share with our customers, enhancing their experience” says Arun Shukla, President and Director, JK Lakshmi Cement.
According to BlueWeave Consultancy, during the forecast period between 2023 and 2029, the size of India cement market is projected to grow at a CAGR of 9.05 per cent reaching a value of US$ 49.24 billion by 2029. Major growth drivers for the India cement market include the growing need from construction and infrastructure sectors and rising governmental initiatives and investments in expansive infrastructure ventures encompassing highways, railways, airports, and public edifices.
Importance of Digitalisation
Digitalisation in cement manufacturing is crucial for several reasons:
- Enhanced efficiency: Digital tools streamline production processes, reducing waste and improving the precision of operations. This leads to higher output and better resource utilisation.
- Predictive maintenance: By leveraging AI and IoT, cement plants can predict equipment failures before they occur, minimising unplanned downtime and extending the lifespan of machinery.
- Energy optimisation: Digital technologies enable the monitoring and optimisation of energy consumption, leading to significant cost savings and a reduced carbon footprint.
This aligns with global sustainability goals and regulatory requirements.
Quality control: Advanced sensors and data analytics ensure consistent product quality by closely monitoring and adjusting the production parameters in real time.
Safety improvements: Automation and robotics reduce the need for human intervention in hazardous environments, enhancing worker safety and reducing the risk of accidents.
Competitive advantage: Companies that embrace digitalisation can respond more quickly to market changes, innovate faster, and provide better customer service, giving them a competitive edge in the industry.
Digital transformation is reshaping the cement industry by driving efficiency, enhancing product quality, and promoting sustainability. As the industry continues to evolve, the adoption of digital technologies will be essential for maintaining competitiveness and achieving long-term success.
Key technologies driving digitalisation
The digital transformation of the cement industry is powered by a suite of advanced technologies that enhance efficiency, improve product quality, and drive sustainability. Here are some of the key technologies making a significant impact:
IoT refers to a network of interconnected devices that communicate and exchange data in real time. In the cement industry, IoT applications are revolutionising operations by enabling real-time monitoring and control of production processes. Sensors embedded in equipment collect data on various parameters such as temperature, pressure, and vibration. This data is then transmitted to a central system where it is analysed to optimise performance. For instance, IoT-enabled predictive maintenance systems can detect anomalies and predict equipment failures before they occur, minimising downtime and reducing maintenance costs. Additionally, IoT helps in energy management by monitoring consumption patterns and identifying opportunities for energy savings.
AI and ML in process optimisation are pivotal in enhancing process optimisation in the cement industry. AI algorithms analyse vast amounts of data generated from production processes to identify patterns and insights that human operators might overlook. ML models continuously learn from this data, improving their accuracy and effectiveness over time. These technologies enable real-time adjustments to production parameters, ensuring optimal performance and product quality. For example, AI-driven systems can automatically adjust the
mix of raw materials to produce cement with consistent properties, reducing waste and improving efficiency. AI and ML also play a crucial role in predictive maintenance, forecasting potential issues based on historical data and preventing costly equipment failures.
Tushar Kulkarni, Head – Solutions, Innomotics India, says, “Adoption of artificial intelligence (AI) will significantly help cement plants in their efforts towards innovation, efficiency and sustainability goals through improved process optimisation and increased productivity.”
“The Innomotics Digi-Suite (AI-based) is positioned to support the cement industry in this endeavour. Built on microservices architecture, Digi-Suite offers flexible self-learning AI based solutions which can be customised or tailor-made in accordance with plant / customer requirements. It enables customers to implement their digitalisation strategies in a stepwise manner and scale it up to an entire plant or multiple plants. Through this platform, customers can monitor and manage processes centrally. This approach provides guidance for company-wide process standardisation, knowledge sharing and optimum utilisation of expert resources,” he adds.
Big Data analytics involves processing and analysing large volumes of data to extract meaningful insights. In the cement industry, Big Data analytics is used for predictive maintenance and strategic decision-making. By analysing data from various sources such as sensors, machinery logs, and production records, companies can predict equipment failures and schedule maintenance activities proactively. This approach minimises unplanned downtime and extends the lifespan of critical assets. Furthermore, Big Data analytics helps in optimising supply chain management, inventory control, and production planning by providing actionable insights into trends and patterns. Decision-makers can leverage these insights to make informed choices that enhance operational efficiency and competitiveness.
Arun Attri, Chief Information Officer, Wonder Cement, says, “The advantages of data integration are substantial. By leveraging integrated data,
we build a single source of truth, we can identify patterns, optimise processes, and implement strategic initiatives that drive overall business growth. This approach not only enhances operational efficiency but also strengthens our relationships with all stakeholders by providing a clear and consistent view of our operations.”
“By establishing a single source of truth, we ensure that all stakeholders, both internal and external, have access to consistent and accurate data. This unified data repository enhances visibility into our operations, improves decision-making, and enables comprehensive analyses. For internal stakeholders, such as our production, quality and maintenance teams, this means having reliable data to optimise processes and schedule maintenance effectively. For external stakeholders, including suppliers and customers, it ensures transparency and trust, as they can rely on the accuracy of the information provided,” he adds.
Cloud computing offers a scalable and flexible solution for data storage and access, playing a vital role in the digitalisation of the cement industry. By storing data in the cloud, companies can easily access and share information across different locations and departments. Cloud-based platforms facilitate real-time collaboration and data sharing, enabling seamless integration of various digital tools and systems. Additionally, cloud computing provides robust data security and backup solutions, ensuring that critical information is protected and can be recovered in case of data loss. The scalability of cloud services allows cement manufacturers to handle the increasing volume of data generated by IoT devices and other digital technologies, supporting their growth and innovation initiatives.
Digital twin technology
Digital twin technology involves creating a virtual replica of a physical asset, process, or system. This digital counterpart is continuously updated with real-time data from sensors and other sources, mirroring the physical entity’s performance, behaviour and condition. In the cement industry, digital twins
offer numerous benefits. They enable real-time monitoring and analysis, allowing operators to visualise and understand complex processes in detail. This enhanced visibility helps in optimising production, improving efficiency, and reducing downtime. Digital twins also facilitate predictive maintenance by simulating various scenarios and identifying potential issues before they occur, thereby extending the lifespan of equipment and minimising maintenance costs. Moreover, they support data-driven decision-making by providing comprehensive insights into operations, leading to better resource management and increased productivity.
Tarun Mishra, Founder and CEO, Covacsis, explains, “Different plant data reside within the walls of individual plants. Comparing micro economic performance across plants is impossible. Covacsis’ IPF is designed to aggregate multiple plant’s data at unified enterprise datalike (historian) which then further used for relative baselining and relative performance analysis across same and similar asset base or product or processes.”
“Data plays the most important role in any algorithm. Big data and fast data are only adding to the logistics performance of any algorithm and platform. Covacsis is a decade old and most mature platform in the world. Covacsis’ SaaS infrastructure is already handling more than 350 billion of cement process and operation data on a daily basis with a compounding daily growth rate of 1 per cent. This provides a significant advantage to Covacsis towards building algorithms and ensuring the value efficacy of these algorithms for the industry,” he elaborates.
The implementation of digital twins in cement plants involves several steps. First, detailed models of the plant’s equipment, processes, and systems are created using data from various sources such as sensors, historical records, and engineering specifications. These models are then integrated into a digital platform that continuously collects and analyses real-time data from the physical plant. For instance, a digital twin of a cement kiln can monitor temperature, pressure, and other critical parameters, allowing operators to optimise the combustion process and improve energy efficiency.
Similarly, digital twins of grinding mills can help in adjusting operational parameters to achieve optimal particle size distribution and improve cement quality. The integration of digital twins with other digital technologies such as IoT, AI and Big Data analytics enhances their capabilities, providing a comprehensive and dynamic view of the entire production process. As a result, cement plants can achieve significant improvements in operational efficiency, product quality and sustainability.
Automation in cement production
Automation plays a pivotal role in enhancing productivity within the cement industry by streamlining operations and reducing the reliance on manual labor. Automated systems and machinery can perform repetitive and complex tasks with higher precision and consistency than human workers. This leads to significant improvements in operational efficiency and throughput. For instance, automated material handling systems can manage the movement and storage of raw materials and finished products more effectively, minimising delays and reducing handling costs.
Automated process control systems enable real-time monitoring and adjustments of production parameters, ensuring optimal performance and reducing waste. Additionally, automation helps in maintaining consistent product quality by minimising human errors and variations in the manufacturing process. Overall, the integration of automation technologies results in faster production cycles, lower operational costs, and increased competitiveness in the market.
The introduction of automation in the cement industry has a profound impact on workforce skills and safety. As automation takes over routine and hazardous tasks, the demand for manual labour decreases, and the focus shifts to more technical and supervisory roles. Workers are required to develop new skills in operating and maintaining automated systems, as well as in data analysis and problem-solving. This shift necessitates continuous training and upskilling to ensure the workforce can effectively manage and leverage advanced technologies.
On the safety front, automation significantly enhances worker safety by reducing their exposure to dangerous environments and tasks. Automated systems can handle heavy lifting, high-temperature processes, and exposure to harmful dust and chemicals, thereby minimising the risk of accidents and occupational health issues. As a result, automation not only boosts productivity but also contributes to a safer and more skilled workforce, fostering a more sustainable and resilient industry.
Energy efficiency and sustainability
Digital tools are revolutionising the way energy consumption is monitored and optimised in the cement industry. Advanced sensors and IoT devices continuously collect data on energy usage across different stages of the manufacturing process. This real-time data is analysed using AI and machine learning algorithms to identify patterns, inefficiencies, and opportunities for energy savings. Energy management systems (EMS) integrate these digital tools to provide a comprehensive overview of energy consumption, allowing operators to make informed decisions to reduce energy waste. For instance, predictive analytics can forecast energy demands and optimise the operation of high-energy equipment, such as kilns and grinders, to align with periods of lower energy costs. Additionally, automated control systems can adjust operational parameters to maintain optimal energy efficiency, thereby reducing the overall energy footprint of the plant.
McKinsey & Company for the cement industry analyse that pursuing digitisation and sustainability levers are key to significantly boosting productivity and efficiency of a typical cement plant. The result is a margin gain of $4 to $9 per tonne of cement, which would shift a traditional plant to the top quartile of the cost curve for plants with similar technologies.
Digital technologies are also instrumental in driving sustainable practices within the cement industry. By providing precise control over production processes, digital tools help in minimising raw material wastage and reducing emissions. For example, advanced process control (APC) systems optimise the combustion process in kilns, leading to more efficient fuel use and lower carbon dioxide emissions. Digital twins, which create virtual replicas of physical assets, enable detailed simulations and scenario analyses, allowing companies to explore and implement more sustainable production methods. Furthermore, the integration of renewable energy sources,
such as solar and wind power, is facilitated by digital technologies that manage and balance energy loads effectively.
Digital platforms also support the implementation of circular economy practices, such as the use of alternative fuels and raw materials, by tracking and optimising their utilisation throughout the production cycle. Overall, digital technologies empower the cement industry to achieve significant advancements in energy efficiency and sustainability, contributing to environmental conservation and compliance with global sustainability standards.
Future of digitalisation
The cement industry is on the brink of a significant transformation driven by emerging technologies. Innovations such as artificial intelligence (AI), machine learning (ML), advanced robotics, and blockchain are poised to revolutionise various aspects of cement production and supply chain management. AI and ML will enable more sophisticated predictive maintenance and process optimisation, reducing downtime and increasing efficiency. Advanced robotics will automate more complex and hazardous tasks, further enhancing productivity and worker safety. Blockchain technology offers potential benefits in enhancing transparency and traceability in the supply chain, ensuring the integrity of product quality and compliance with environmental regulations. These emerging technologies will collectively contribute to a more efficient, reliable, and sustainable cement industry.
Smart cement plants represent the future of the industry, where digital technologies are fully integrated to create highly automated and interconnected production environments. In these plants, IoT devices, digital twins and AI-driven systems will work together seamlessly to monitor, control and optimise every aspect of the manufacturing process. Real-time data from sensors will feed into advanced analytics platforms, enabling instant adjustments to maintain optimal performance. Digital twins will allow operators to simulate and test changes in a virtual environment before implementing them in the physical plant, minimising risks and enhancing decision-making. Furthermore, smart cement plants will incorporate renewable energy sources and energy storage solutions, supported by intelligent energy management systems that ensure efficient and sustainable operations.
Over the next decade, the digital transformation of the cement industry is expected to accelerate, driven by continuous advancements in technology and increasing demands for sustainability. We can anticipate widespread adoption of AI and ML for real-time process optimisation and predictive maintenance, leading to significant reductions in operational costs and emissions. The use of digital twins will become standard practice, enabling more precise and flexible production planning and execution.
Enhanced connectivity and data sharing across the supply chain will improve efficiency, transparency, and collaboration among stakeholders. Additionally, the integration of renewable energy and advanced energy storage solutions will become more prevalent, supported by digital platforms that optimise energy usage and reduce environmental impact. As the industry embraces these digital innovations, we will see a new era of smart, sustainable, and highly efficient cement manufacturing, positioning it to meet the challenges and opportunities of the future.
Conclusion
The digital transformation of the cement industry is poised to revolutionise traditional manufacturing processes, driving significant advancements in efficiency, sustainability, and competitiveness. Emerging technologies such as IoT, AI, ML advanced robotics, and blockchain are not only optimising energy consumption and improving operational efficiency but are also paving the way for more sustainable practices. The evolution towards smart cement plants, where digital tools are fully integrated, is set to redefine production environments with enhanced automation, real-time monitoring and advanced analytics.
Over the next decade, we can expect these technologies to become standard practice, leading to substantial reductions in costs and emissions, improved supply chain transparency, and greater adoption of renewable energy sources. As the industry embraces digitalisation, it will be better equipped to meet future challenges and seize new opportunities, ultimately contributing to a more sustainable and resilient
global economy.
– Kanika Mathur
Concrete
Advantages of data integration are substantial
Published
3 months agoon
August 23, 2024By
RoshnaArun Attri, Chief Information Officer, Wonder Cement, discusses the digital transformation and advanced technologies used to enhance operational efficiency, sustainability and cybersecurity in their cement manufacturing processes.
How has the implementation of IT initiatives transformed your operations and processes in the cement industry?
We operate under the digital vision: To leverage digital to accelerate growth, build relationships and enhance consumer experience.
Our digital transformation initiatives have profoundly reshaped operations and processes at Wonder Cement. By integrating advanced technologies such as IoT, cloud computing and constructing a data lake house for data consolidation as a single source of truth, we have enabled seamless information flow between applications and developed real-time analytics. These advancements have streamlined our production processes, enhanced operational efficiency, and improved decision-making. Additionally, predictive analytics allows us to anticipate market trends and customer needs more accurately.
Can you discuss how your organisation is adopting Industry 4.0 technologies and the benefits you are experiencing?
Embracing Industry 4.0 technologies is truly transforming our operations and improving reliability. Here are the key benefits we are experiencing:
- Real-time monitoring: IoT devices provide real-time data on equipment performance, enabling predictive maintenance and reducing downtime.
- Process optimisation: AI and machine learning algorithms enhance process optimisation,
leading to increased efficiency and reduced operational costs. - Higher productivity: Improved monitoring and optimisation result in higher productivity and better product quality.
- Enhanced sustainability: Better resource utilisation contributes to enhanced sustainability.
What specific automation technologies have you implemented, and how have they improved efficiency and productivity in your cement plants?
Automation technologies have revolutionised efficiency and productivity at our cement plants. Automated quality control systems ensure consistent product quality by continuously monitoring and adjusting production parameters. Robotic process automation (RPA) in administrative functions like inventory management and order processing has drastically reduced manual errors and boosted operational efficiency. These advancements enable us to uphold high standards of precision and reliability, optimise resource utilisation and minimise wastage.
How are predictive analytics and maintenance technologies being utilised in your operations to minimise downtime and optimise maintenance schedules?
Predictive analytics and maintenance technologies are pivotal in minimising downtime and optimising maintenance schedules at Wonder Cement. By analysing historical data and real-time sensor inputs, we proactively predict and address potential equipment failures. This approach has drastically reduced unplanned downtime, enhanced equipment reliability, and extended machinery lifespan. Our maintenance teams use these insights to schedule activities during planned shutdowns, ensuring minimal production disruption. This proactive strategy has led to substantial cost savings and significantly boosted overall plant efficiency.
What are the challenges and advantages of integrating data across various systems in your cement manufacturing process?
Integrating data across various systems in our cement manufacturing process presents both challenges and advantages. One of the primary challenges is ensuring data consistency and accuracy across different platforms. To address this, we have implemented robust data integration and validation frameworks that facilitate seamless data flow and synchronisation.
The advantages of data integration are substantial. By leveraging integrated data, we build a single source of truth, we can identify patterns, optimise processes, and implement strategic initiatives that drive overall business growth. This approach not only enhances operational efficiency but also strengthens our relationships with all stakeholders by providing a clear and consistent view of our operations.
By establishing a single source of truth, we ensure that all stakeholders, both internal and external, have access to consistent and accurate data. This unified data repository enhances visibility into our operations, improves decision-making, and enables comprehensive analyses. For internal stakeholders, such as our production, quality and maintenance teams, this means having reliable data to optimise processes and schedule maintenance effectively. For external stakeholders, including suppliers and customers, it ensures transparency and trust, as they can rely on the accuracy of the information provided.
How is digitalisation contributing to sustainability efforts and reducing the environmental impact of your cement production?
IT initiatives play a pivotal role in supporting our sustainability efforts and reducing the environmental impact of cement production at Wonder Cement. One of the key contributions of IT is the optimisation of energy consumption. Through advanced energy management systems, we continuously monitor and analyse energy usage across our operations. This allows us to identify areas of inefficiency and implement measures to reduce energy consumption, such as adjusting process parameters and utilising energy-efficient equipment.
Additionally, IT enables us to track and manage emissions more effectively. By integrating emission monitoring systems with our IT infrastructure, we can continuously measure and analyse emission levels, ensuring compliance with environmental regulations and identifying opportunities for reduction. For instance, real-time data on CO2 emissions allows us to adjust our production processes to minimise the carbon footprint.
IT initiatives also facilitate the implementation of circular economy practices. Through sophisticated waste management systems, we can monitor and optimise the use of alternative fuels and raw materials, reducing our reliance on traditional resources and minimising waste generation.
With the increasing digitisation of operations, what steps are you taking to ensure cybersecurity and protect sensitive data?
With the increasing digitisation of operations, ensuring cybersecurity and protecting sensitive data is paramount at Wonder Cement. We have implemented advanced technologies such as artificial intelligence and machine learning (AI/ML) for threat detection and response, and Secure Access Service Edge (SASE) to provide secure and efficient network access. Additionally, our Security Operations Centre (SOC) continuously monitors our digital infrastructure, utilising AI/ML to identify and mitigate potential threats in real-time. Comprehensive cybersecurity measures, including firewalls, intrusion detection systems, and regular security audits, further safeguard our systems. We also conduct regular training sessions for our employees to raise awareness about cybersecurity best practices and potential threats. By prioritising cybersecurity, we ensure the confidentiality, integrity, and availability of our critical data and systems, staying ahead of emerging cyber threats.
What future IT trends do you foresee having the most significant impact on the cement industry, and how is your organisation preparing to embrace these trends?
Looking ahead, we foresee several IT trends that will significantly impact the cement industry. These include the further integration of AI and machine learning for advanced process optimisation, the adoption of blockchain technology for transparent and secure supply chain management, and the expansion of IoT applications for enhanced monitoring and control. Additionally, the use of drones for site inspections, computer vision for quality control, generative AI for innovative design solutions, and robotics and RPA for automating repetitive tasks will bring substantial benefits. At Wonder Cement, we are actively preparing to embrace these trends by investing in research and development, collaborating with technology partners, and continuously upgrading our IT infrastructure. Our proactive approach ensures that we remain at the forefront of technological advancements, driving innovation and maintaining our competitive edge.
– Kanika Mathur
At the World Cement Association’s annual conference the WCA Director, Emir Adiguzel addressed the global cement industry to outline the challenges and opportunities facing the global cement industry.
The conference held in Nanjing, had industry leaders, innovators and stakeholders in attendance to discuss the future of cement production and sustainability. The WCAA director emphasised on the cement industry’s stern commitment to sustainability; spoke about the global cement demand and market dynamics, projecting a period of stagnation from 2024-2030 with growth expected only in the Middle east, India and Africa; about the challenges and opportunities in carbon capture technology hat show promise but will need further development and substantial investment as well as about the strategic initiatives and collaboration within the industry in improving sustainability and operational performance.
Adiguzel concluded his address by highlighting the crucial point where the global cement industry stands by saying “Collaboration within the World Cement Association is essential for sharing knowledge and aligning on long-term objectives. Ensuring the industry’s resilience and adaptation to evolving market dynamics is crucial for the survival of independent cement producers”.