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Technology trends in cement manufacturing

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7 years ago

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– Dr Anjan K Chattejee

What have been the visible technological advancements in cement manufacturing during the last decade?
The cement industry in the world has grown phenomenally in the last decade and the production level of all varieties of Portland cements taken together has crossed four billion tonnes, which is the largest volume amongst all manmade materials. Such growth has been possible due to considerable advances made in the hardware and software of cement manufacture. The main drivers for these technological advances have so far been the ‘cost’ and ‘quality’ of products. The technological progress has been multi-dimensional as reflected in the following features:
1. The capacity of a single kiln for clinker making has reached 12,000-13,000 tonne (t) per day, although in the recent years there is a trend of installing kilns of lower capacity due to economic and logistics reasons.
2. With automation, instrumentation, computer-aided controls and integration of expert systems the man-hours per tonne of cement came down to one or even less, thereby reducing the application of human discretion and increasing the dependence on electronic gadgets.
3. The choice of grinding systems for raw material and clinker has been dependent on the better energy utilisation factor, which has led to more extensive adoption of vertical roller mills, high-pressure roll presses and horizontal roller mills.
4. The fourth generation clinker coolers are now available from several suppliers, operating with 75 per cent efficiency of the theoretical maximum.
5. Significant developments have taken place in multi-channel burners, which have been specifically designed for co-incineration of alternative fuels.
6. The efficiency of the thermal process inclusive of raw materials drying has now touched almost 80 per cent of the theoretical maximum.
7. Driven by the rising prices of power and fuel, experiencing concerns about grid reliability, and fulfilling the commitments to sustainable development, the cement industry has taken more interest in ‘waste heat recovery’. While the most common water-steam cycles operate at heat source temperatures as low as 3000C, for heat recovery from still lower temperatures, the Organic Rankin Cycle, utilising organic compounds as process flows or the Kalina Cycle, using a water-ammonia solution, are now available for implementation in cement plants.
8. For sustainable production, the AFR use has taken deep root in the operational philosophy. Depending on the social conditions, living habits, availability of AFR and its collection systems, the extent of use varies from country to country, although the objective is to maximise its use.
9. Process measures and secondary abatement technologies ensure low emissions of dust, NOx and SOx in all modern plants. Recently additional focus has been laid on emissions of mercury and carbon dioxide. In parallel, there has been significant progress in developing continuous emission monitoring systems.
10. There has been widespread application of computational fluid dynamics (CFD) and of physical simulation and modelling in solving process and design problems.What are your observations on the progress achieved in reducing the energy consumption in manufacturing?
The global average thermal and electrical energy consumption levels are reportedly 800-850 kcal/kg of clinker and 100-110 kWh/t of cement. Compared to these levels the average specific energy consumption values in India are 725 kcal/kg clinker and 82 kWh/t cement and the corresponding best values obtained are 667 kcal/kg and 68 kWh/t. From these values it appears that globally there is still enough scope for better energy management, while in India the potential of energy conservation is rather limited.
In this context, it is important to note that more rigorous environmental norms will, of course, reduce the emission loads but at the cost of energy. Further, stricter specifications of products, more stringent control of particle size requirements, use of non-carbonate alternative materials, etc. are expected to integrate new or additional process measures, which might increase the energy consumption. Hence, the potential of further energy conservation in our country in particular will depend on the future course of product quality and environmental demands. In addition, the limitations of plant vintage, design and layout may act as obstacles in achieving further energy conservation.Are you satisfied with the research done on low- and off-grade limestone?
While the use of low- or off-grade limestone is not a critical concern in many countries, it is certainly an issue that needs to be dealt with more seriously in our country, as it can create 25-30 per cent additional resource base for the rapidly expanding industry. Limestone having CaO content of less than 42 per cent and limestone containing impurities of high silica or high magnesia or high iron content fall in this category and viable technologies for their use will be of immense economic benefit. Researches in this field, however, are sporadic and academic. The current technologies are limited to ‘sweetening’, wobbling, belt sorting, and froth flotation.
The newer technological options of photometric sorting, electrostatic separation, bioleaching, or making products not conforming to the conventional types, continue to be exploratory in their development. On the contrary, utilisation of marginal grade limestone by the cement industry deserves a ‘mission’ status in our country. Since dry manufacturing systems can these days co-exist with wet preparation of raw materials, improved froth flotation and bioleaching techniques cannot be ignored.
More logical perhaps is to look at new products and new processes, High-belite cement and high-magnesia blended cement are examples of such possibilities. Use of dolomitic limestone for simultaneous manufacture of cement and magnesia is a technology worth re-examining. Broadly speaking, it is time to lay much greater emphasis on research on utilising low-grade limestone.What is the status of research for enhancing the use of high-ash coal?
We all know that the cement industry has been a very effective user of high-ash coal. The kiln burners are designed suitably to combust high-ash coal and the plants make use of coal with ash content of 35-40 per cent in most cases. Mixing of coal with varying ash contents has also been in practice to facilitate the use of high-ash coal. Several attempts were made in the past to install small captive coal washing units in a few cement plants to upgrade the quality of coal for process consumption but not with success due to economic and operational reasons. A few pit-head coal washing plants are operating in the country to de-ash non-coking coal prior to supply to the cement units and other users. The aforesaid measures do not seem to be adequate to meet the future demand of clean coal. Hence, for enhancing the use of high-ash coal further it would be important to integrate the technology of coal gasification with the cement manufacturing process.
Technologies for coal gasification are decades old but their integration with the cement manufacturing process needs specific development with regard to the operational features and economic viability. It is pertinent to mention here that coal gasification is attractive from the economic and energy security perspectives but the overall carbon intensity is much higher than coal mining. The technology is also water-intensive. Nevertheless, the abundantly available resource of high-ash coal in the country needs to be considered an object of priority in meeting the energy demand by adopting such a technology. It is interesting to note that China has laid out plans to produce 50 billion cubic metres of gas from coal by 2020, enough to satisfy more than 20 per cent of total gas demand. Despite the stated environmental shortfalls, the technology has been introduced in order to exploit the stranded coal deposits sitting thousands of kilometres away from the main industrial consuming centres, as transportation of gas is deemed cheaper than transporting solid fuel. It might also be pertinent to mention here that in some countries the adverse environmental problems of gasification technology has led to considering the alternative ‘underground coal gasification’ process.
In brief, the process involves pumping oxygen and steam through a small borehole into the coal seam to cause local combustion. The synthetic gas product consisting of hydrogen, methane, carbon monoxide and carbon dioxide is siphoned off through a second borehole and is collected, transported, stored and used. It is reported that the underground coal gasification process substantially reduces the CO2 emission.
While on the subject, another widely known clean coal technology of ‘coal bed methane’ deserves a mention. The process is relevant for coal deposits that are too deep to mine. Water is sucked out of the seam and methane attached to the surface of the coal seam is freed and then collected. The CBM technology is said to have fundamentally changed the dynamics of the gas industry in Australia.
Considering the plethora of options for clean coal technology, it is important for the cement industry to be more involved in coal research but in a co-ordinated national strategy, as it cannot be handled at the individual company level.What is the progress in real-time analysis for QC in cement plants?
Recent developments in the use of x-ray diffraction are changing the traditional methods of quality and process control, as they have the ability to measure mineral phases or compounds formed directly in real time. Cement and clinker production involves chemical reactions to produce precisely controlled blends of phases with specific properties. So far there has been overwhelming dependence on either off-line or on-line oxide or elemental analysis of raw or in-process materials for QC.
Methods and equipment are now available for continuous quantitative on-stream analysis of the mineral or phase composition of cement and clinker. The instrument is a stand-alone piece of equipment, which is installed at the sampling point. A sample for analysis is extracted from the process stream and after due preparation on-line the sample passes through the x-ray beam.
The diffracted x-rays are collected over 0 to 1200 by a detector. The Rietveld structural refinement technique is applied to analyse the resulting diffraction pattern. The analysis of the moving stream is done in close frequency of, say, once every minute. All analysis results are communicated directly to the plant PLC system. The real-time measurement of the mineral composition of cement and clinker for process control is a paradigm shift for the cement industry. The discernible benefits of using on-stream x-ray diffraction are the following:

  • Control of kiln burner based on free lime, clinker reactivity, alkali and sulphur contents
  • Control of cement mill separators and feed rates and proportions to achieve consistent cement strength at minimum power consumption
  • Control of gypsum dehydration through cement mill temperature to give consistent setting times
  • Control of mill weigh-feeders for different feed materials.

The net advantages of implementation of such on-line QC systems are the optimum performance and cost, reduced risk of product failure and consequent marketing benefits.
Another development in the on-stream analysis, apart from the widely used bulk analyser based on Y-radiation, is the application of infrared spectra that are provided by the stabilised white light source. The light illuminates the target bulk material to be analysed as it passes the unit on an existing conveyor belt. The infrared radiation excites vibrational oscillations of the molecular bonds in the material under test, which results in reflection and absorption spectra that are characteristic of minerals being analysed.
The Near Infrared (NIR) ranges are applied for analysing limestone materials. It is claimed that the IR based on-line bulk analyser shows better performance for the cement raw material constituents than the traditional Y-ray equipment. One additional advantage in this new development is the avoidance of potentially hazardous excitation sources.What would you like to highlight as significant technological steps in pyro-processing?
Over and above the standard features of a large-capacity modern 5/6 stage preheater kiln with precalciner at one end and efficient clinker cooler at the other, a specific mention may be made of the advent of two-support kiln systems. Compared with the traditional three-support kilns, the two-support kilns offers the following advantages: saving of space, reduced kiln surface heat loss, lower machine weight and less foundation requirements, elimination of kiln girth gear and reduced number of supporting rollers, lower risks of kiln shell ovality and misalignment of kilns. Hence, the general acceptance of two-support kilns is likely to increase.
The second notable development is the introduction of low-NOx burners, based on the principle of staged combustion. Further, the preheater-precalciner system can now be tailored to suit the primary and secondary fuels used for burning operation. It is possible to install low-NOx calciner with longer residence time, calciner with ignition module for ignition in pure air, or calciner with an integrated chamber for ignition of fuel in pure air at high temperature. It is also possible to introduce in the system a specially designed combustion chamber, such as the ‘Hotdisc’ of FLS, for alternative difficult-to-burn lumpy fuels.
The third important development is the secondary abatement technology for NOx with selective non-catalytic reduction. We also see more efficient on-line systems for SOx abatement. Similarly, secondary abatement systems for VOC will find application, where necessary.Which are the technological developments of significance in the grinding process?
For the comminution equipment the development of construction materials with high wear resistance is of great significance. In roller mills, where there are contradictory demands of both ductility and hardness, the new materials provide longer life with reduced maintenance. An example of the new material is the double casting for roller tyres, in which high-chromium alloy inserts or bars are incorporated into a ductile iron base. The second example is a metal matrix composite in which the high-chromium alloy is reinforced with ceramic particles. The layer of ceramic particles is evenly distributed over the surface in a honeycomb pattern.
The surfaces of roll presses are also vulnerable to damage and hence, like the VRMs, the main aim of continued design development for roll presses has been to achieve higher operational reliability of the surfaces. Using wearing parts of chilled cast material, or the composite material build-up with buffer layers with a wear-resistant top layer, or fabrication of two-piece grinding rolls consisting of a shaft with shrunk-on tyre with welded hard layer as armour are some of the illustrations of these developments.
In addition to the material development for the mill systems, the progress in the commercialisation of ‘horomills’ is worth noting. More than 50 industrial references are now available globally. The tentative single mill capacity for raw meal and normal Portland cement ranges up to 180 t/h and 425 t/h respectively. Two mills installed together can raise the corresponding output levels to 680 t/h and 280 t/h.
The horomill covers the same application fields as conventional ball mill, VRMs and roll presses and the industrial operations have shown energy savings ranging from 35per cent to 60 per cent. Since the horomills have compact integrated drives like those of ball mills, it is comparatively easy to install within a limited space. The system includes auxiliary equipment such as the classifier, filter and bucket elevator. One of the advantages of a horomill seems to be its production flexibility, thanks to the small quantity of material in grinding and separating circuit.What are your observations on the present trends of process control and
‘expert systems’?
The control systems in the modern plants consist of human-machine interfaces, control software, and programmable logic controllers. They include data packages that can bring out trends of control parameters, alarm provisions and even log
details of shift operators. These packages have large flexibilities to change the graphics and control logic and the unit processes are controlled from a central control room.
The process instrumentation has expanded considerably and computer models are used to operate complex processes. Fuzzy-type or rules-based logic gained wide popularity in the 1990s and its use is continuing more extensively. Kiln optimisation and mill control are all predominantly based on rules-based fuzzy. However, after being on the fringe for many years, the latest versions of neural net technology and model-based predictive techniques are coming to the fore as competitive options.
The expert packages such as ABB Expert Optimiser/Linkman with logical dynamic modelling tools, FLS Automation ECS/ProcessExpert integrating camera signals and soft sensors, Pavillion8 MPC, Powitec PIT Indicator/Navigator. Lafarge LUCIE, Polexpert KCE/MCE are some of the advanced systems in the market. The ramp-up in the market for expert systems in future would depend more and more on integration with high-quality soft sensors of in-process materials, camera signals, on-line particle-size analysers, etc. Further, many supervisors and laboratory managers have started making use of remote access software to communicate and to provide assistance to the plant.
The next phase of control strategies seems to be heading towards intelligent field devices that use self-diagnostics and can electronically communicate specific instructions to the maintenance set-up of the plant. There is no doubt that technologically the plant control systems are progressing quite rapidly and are turning out to be more sophisticated.Do you foresee any disruptive technology coming to the cement industry?
Disruptive technologies can come from researches in two directions – one, developing new manufacturing processes for Portland cement and, another, new cement that is generically different from Portland cement. As far as the manufacturing process is concerned, the rotary kiln technology has become deep-rooted in practice and created a firm position for itself with preheater-precalciner subsystems for large-scale Portland clinker production.
Several alternative processes have been attempted during the last four decades, which include vertical shaft kilns, fluidised-bed process, conveyor kilns, microwave heating, radiation synthesis, sol-gel process, melting and quenching and a few other options. Excepting the vertical shaft kiln technology and the fluidised-bed process, all other routes for clinker making have remained in the realm of academic research. Industrialisation of the vertical shaft kiln technology flourished in some countries but ultimately it lost ground to the rotary kiln technology in respect of viability and scale of operation.
Similarly, the fluidised-bed process has been used for small capacity plants; engineering designs have been prepared up to 3000 t/d capacity, but its competitiveness with large-scale clinker making in rotary kilns could not be established so far. Hence, in manufacturing terms, no disruptive technologies can at present be forecast.
For alternative binders the research has been continuing almost since the Portland cement was born. The persistent research efforts led to the invention of three new generic cements, viz., calcium aluminate cement, calcium sulfo-aluminate-belite cement, and alinite cement. All the three binders have certain merits that are not found in Portland cements but they have certain serious shortcomings, which prevent them to qualify as alternatives to Portland cements.
Calcium aluminate cement shows retrogression of strength at higher temperatures, calcium sulfo-aluminate cement requires high-cost raw materials and alinite cement has the strong probability of releasing chlorine during hydration. All these binders are good for niche applications and not for substituting Portland cements as all-purpose structural cements.
Hydraulic cements based on magnesium oxide have recently been claimed to offer great potential for reducing CO2 emission. These binders are in the process of development and use either magnesium carbonate or magnesium silicate as the raw material. It seems that this direction of development has considerable potential for scaling up and commercialisation. There has also been a considerable research on the manufacture of cement and concrete by carbonation instead of hydration.
One trend of development in this category uses either seawater or brine as raw material and another direction is to synthesise a low-calcium silicate clinker. In both the research directions the objective is to recycle CO2 from the captured flue gases for carbonation. The global effectiveness of this approach will depend on the extent to which a circular economy for CO2 develops. The environmental compulsions for CO2 recycling with value addition cannot be ignored, particularly in view of the fact that the known approach of CO2 capture and sequestration is unviable for the cement manufacturing process.
Looking at the overall scenario of product development, one may arrive at the conclusion that no disruption in Portland cement manufacture is predicted as of now. Hence, the production of blended cements with supplementary cementing materials will continue globally. Some niche markets will be served by the new binders and, more particularly, by the belite-rich Portland cement, calcium sulfo-aluminate cement, calcium aluminate formulations, alinite cement, and carbonated binders and concrete. The emergence of magnesia-based cements should not be lost sight of in this melee.Dr Anjan K Chattejee is an international personality in cement, and is presently associated with development of LC3 cement and advisor to Pidilite industries. He is Former Wholetime Director of ACC Ltd, Mumbai and Chairman, Conmat Technologies Pvt Ltd, Kolkata.

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Concrete

Digital technologies are transforming safety

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1 month ago

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August 11, 2025

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Raju Ramchandran, SVP and Head Manufacturing – Eastern Region, Nuvoco Vistas, on how the company is setting new benchmarks in industrial safety and operational resilience, with smart technologies and a proactive approach.

In the high-risk environment of cement manufacturing, safety is more than a compliance requirement—it is a strategic imperative. Raju Ramchandran, SVP and Head – Manufacturing, Eastern Region, Nuvoco Vistas, shares how the company is redefining workplace safety through technology, accountability and next-generation systems. In this in-depth conversation, he outlines the evolving risks, robust safety frameworks and the future of digital-first safety culture.

How has the approach to safety evolved in cement manufacturing over the past decade?
Over the past decade, safety in cement manufacturing has evolved from being a regulatory checkbox to becoming an intrinsic part of organisational culture. At Nuvoco, safety is not just a priority, it is a core value, deeply woven into the way we operate every single day. Guided by our ‘Zero Harm’ philosophy, we strive to ensure that every individual stepping into our premises returns home safely.
We have moved towards a more proactive and preventive approach and building strong behavioural safety practices. Specialised training programmes, regular incident reviews and active Safety Committee engagements have strengthened accountability and vigilance across all units. Initiatives such as Cross-Unit Safety Audits, improved workplace hygiene standards, and the successful rollout of the ‘Safety Buddy’ programme reflect our emphasis on collaboration and shared responsibility for safety.
Additionally, best-in-class measures from mandatory safety nets and harnesses to advanced risk assessments for high-hazard tasks are now standard practice across our sites. Supported by leadership commitment, digital monitoring tools and real-time feedback mechanisms, these efforts have transformed safety from a procedural obligation into a shared mindset.
At Nuvoco, safety is a non-negotiable tenet—it is a way of life, and we are constantly raising the bar to protect every member of our workforce.

What are biggest safety risks unique to cements plant today?
Cement manufacturing is an intense, high-temperature and operation-heavy process, where safety is paramount at every stage. The environment presents several unique risks that require constant vigilance and robust preventive measures.
Mining operations within the industry bring their own set of hazards, with strict adherence to Directorate General of Mines Safety (DGMS) guidelines being essential. Exposure to dust is another area of concern, necessitating advanced dust suppression systems and protective equipment to safeguard workers’ health.
Electrical safety and proper energy isolation are also crucial, given the complexity of the equipment involved. Confined space entries, conveyor belt operations and machine guarding present additional risks that call for specialised procedures and continuous monitoring to prevent accidents. Preheaters and precalciners also pose challenges during maintenance activities, such as cleaning cyclone jams, while fire hazards remain present in areas with flammable materials. Additionally, working at heights continues to be one of the major risk activities, making stringent fall protection protocols a non-negotiable.
At Nuvoco, we tackle these risks with a layered approach combining engineering controls, digital monitoring and rigorous safety protocols backed by continuous training and regular mock drills to ensure preparedness for any eventuality. Safety is an unwavering commitment to safeguarding everyone who works in and around our plants.

What role does technology play in enhancing plant safety?
Digital technologies are transforming safety management in cement manufacturing, enabling a shift from reactive measures to a predictive and preventive approach. At Nuvoco, we leverage cutting-edge tools and systems to minimise risk, strengthen hazard management and create safer workplaces for everyone.
Our advanced energy isolation systems such as Lock Out, Tag Out, Try Out (LOTOTO) processes are in place to safeguard electrical operations, while machines are fitted with Visual Cutoff Switches (VCS) for enhanced local control. GPS and Vehicle Tracking Systems (VTS) ensure the safe movement of commuting vehicles across sites.
Real-time monitoring through IoT sensors allows us to track critical parameters like, temperature fluctuations, harmful gases in coal mills and machinery vibrations. These early alerts help prevent potential fires, explosions, and equipment failures. To limit human exposure to hazardous environments, drones are used for inspecting kilns, chimneys and high structures during shutdowns, while robots perform cleaning tasks in preheaters and confined spaces, keeping people out of high-risk areas.
We have also introduced devices such as gas detectors and real-time location trackers that enables faster emergency responses.
Complementing these efforts, our STARS (SHE [Safety, Health & Environment], Tracking, Analysis and Reporting System) software ensures comprehensive tracking of leading and lagging indicators, while mobile apps enable instant reporting of near misses, safety observations and audits. These tools ensure quick corrective actions and strengthen our safety culture across all operations.
By embedding technology into every layer of safety management, Nuvoco has built a digitally enabled, proactive safety framework—one that not only mitigates risks but empowers employees to work confidently, knowing their well-being is protected at every step.

How do you ensure contractor and third-party compliance with your safety standards?
Ensuring contractor and third-party compliance with safety standards in the building material industry involves a comprehensive process that spans prequalification, onboarding, active supervision and post-contract evaluation. It begins at the selection stage, where contractors are assessed not only for their technical competence but also for their safety track record, relevant certifications, availability of personal protective equipment, and the preparedness of their personnel. These expectations are formalised through contractual agreements that clearly outline health and safety responsibilities, legal obligations and consequences in case of non-compliance.
Prior to starting work, contractors undergo mandatory onboarding and training, which cover site-specific hazards, protocols and emergency procedures often communicated in local languages to ensure clarity. For high-risk activities such as hot work, working at heights or confined space entry, a permit-to-work system is in place, supported by detailed risk assessments jointly signed by contractor representatives and plant personnel to reinforce
shared accountability.
During execution, trained supervisors are deployed to monitor compliance on the ground through daily toolbox talks, spot checks and documented audits. Safety performance is closely tracked using both leading and lagging indicators, such as participation in safety initiatives, near-miss and injury reporting. In the event of repeated violations, appropriate enforcement actions are taken, ranging from temporary work stoppage and financial penalties to permanent disqualification while contractors demonstrating consistent adherence are recognised through structured reward and recognition programmes.
Towards the end of the contract period, each contractor’s safety performance is formally reviewed, with the insights feeding into future selection processes. This continuous cycle of evaluation and improvement ensures that safety expectations remain consistent across all stakeholders working within the plant environment.

How are you investing in next-generation safety equipment or systems?
We are investing in next-generation safety systems that not only reduce risks but also transform the way hazards are detected, monitored and controlled across our operations.
We have invested in IoT-enabled sensors provide real-time insights into high temperatures, carbon monoxide levels in coal mills, oxygen levels in pyro processes, and vibrations in heavy machinery, while flame detection via CCTV ensures early alerts for potential fire incidents.
Robotic descalers are used for refractory de-bricking inside preheaters, while drone surveillance is deployed to inspect tall structures such as stacks and silos. This helps identify structural hazards, material build-up and assess the condition of coatings in silos and preheater cyclones. These technologies significantly reduce human exposure to high-risk areas while improving inspection accuracy and efficiency.
Furthermore, we have strengthened fire and explosion protection with advanced suppression systems in coal mills and dust collectors, supported by thermal imaging, we are also exploring the use of AI-enabled cameras for instant detection and response. In hauling operations, driver fatigue detection cameras provide real-time alerts to prevent accidents, while environmental safety is reinforced through live dust monitoring systems with alarms and visual displays at plant gates for corrective action. By embracing these next-generation technologies, we are building a safer, smarter and sustainable world.

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Concrete

Sustainability for Packing Excellence

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2 months ago

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August 5, 2025

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Frank Ormeloh, Business Unit Manager for Cement, HAVER & BOECKER, discusses how packing equipment manufacturers enhance efficiency and sustainability.

When we hear the word ‘sustainability,’ many people jump to a definition that focuses solely on environmental impacts. However, in the truest sense of the word, sustainability encompasses three factors — social, economic and, of course, environmental.
As with all businesses, cement plants have been drawn into the sustainability conversation. As pressure mounts to save resources and reduce carbon footprints and energy consumption, cement plants are developing smart and efficient practices to meet strict environmental standards. To reach sustainability objectives, facilities need to scrutinise the entire plant to identify the most effective solutions. Yet many operations overlook packing and loading lines, writing them off as insignificant to sustainability. However, plants can reduce resource consumption and improve product protection by optimising every system and that includes the packing process.
Some key areas to focus on while optimising a plant for sustainability include choosing the right equipment and components that can be customised to the plant as well as considering machine designs that allow for upgrades and enhancements. These options increase the longevity of the packing line while improving filling accuracy and reducing lost product.

Cleanliness, health and safety
Many producers believe dust is an inevitable byproduct of cement production. This is a myth. It is true that packing powdered material, for example, requires the addition of air to move the material, inevitably creating dust. However, dust suppression technology available today can offer nearly dust-free working conditions. By reducing dust, minimising product loss and promoting the careful use of resources, the employee, the environment and the bottom line all benefit. Maintaining cleanliness also enhances employee health and provides a safer working environment. Reducing dust is just one way to enhance sustainability in a packing plant, though. Adjustments at nearly every stage of the filling process — from feeding and dosing to packing and loading — can have a positive impact.

Feeding and dosing
The first step in the packing process is when material is fed into the packer silo. The material is then moved through a rotary feeder and a dosing system. In this initial step, many machines feature a slide gate dosing unit, which leaves a gap of several millimeters where dust and spillage can escape. To reduce dust production and protect against spillage, operations should consider a fully enclosed, metal shaft-sealed system featuring a rubber interface between the gates. This simple changeout makes the process at least 70 per cent cleaner and up to eight per cent faster compared to traditional slide gate systems. The only dust and spillage that can escape using this system comes from the way the filling spout and the bag valve interact — a challenge that some manufacturers are prepared to address with services such as updated bag sealing technology.

Sealing technology
Advanced sealing technology goes a long way in addressing material loss during bag filling and sealing. Standard rigid filling spouts require the unsealed valve bag to adhere to the tube, leaving room for product to escape. Once packed, unsealed valve bags rely on the inner pressure of the bag to close, which results in the bag being only 70 per cent closed and leaves a 30 per cent opening for spillage.
To solve this challenge, premium manufacturers offer specialized inflatable filling tubes that hermetically seals the gap between the bag and the filling spout during the filling process. This translates to no dust escaping through the valve and, when filling is complete, the bag is removed from the spout and the valve is welded shut by an ultrasonic sealing unit. This creates a cleaner working environment with less product loss, cleanup and energy consumption and better weight accuracy. During palletizing, transportation and storage, these completely sealed bags can make producers stand out with custom designs and a clean packing solution.

FFS technology
Another factor that should be considered for reducing product loss is the type of bag, and its compatibility with the packing equipment. Specialised manufacturers analyse the material being packed and the bags used before making recommendations. These customised recommendations increase the harmony between the bags, packing machines and product. For example, tubular film bags are ideal as a completely sealed, weatherproof and leakproof solution for a wide range of industries, spanning from cement to building and chemical products.
Tubular film is fed into a packing machine where it is cut and sealed, ensuring it is 100 per cent closed. This sealing method creates a permanent, tamper-resistant closure that holds up reliably during transport and storage — a key advantage over other methods that may weaken under shifting conditions. These tubular film bags are also completely emptiable, eliminating product loss for the consumer. Plus, they are recyclable, providing an additional sustainability benefit.
If making the switch to a Form-Fill-Seal (FFS) or tubular film machine, consider the manufacturer and the machine itself. Some FFS machines use vacuum methods to compact material as it’s filled into the bag. On the other hand, some machines are equipped with vibration technology to accomplish this task, which is much more effective and allows for the same amount of product to be packed into a smaller bag, meaning less film used per bag.
Over time, this translates to significant environmental and economic advantages. The fully sealed bags remain clean and uniform, which can draw in more customers. The weatherproof qualities of these bags make handling and storage easier.

Automation at play
Once equipment and bag material choices have been made, it’s time to look at automation, which helps significantly impact efficiency and sustainability. A fully automated packing line allows for more flexible line layouts and negates the inefficiencies caused by human error or manual limitations. Though both may seem like small matters, the effects add up over time. Automation also allows skilled labor to focus on higher-value tasks, improving overall workforce utilisation.
Manual processes, such as bag placement, leave room for lost productivity and errors from tired or distracted workers, who may be late placing a bag on the filling spout or miss a bag entirely. If a bag is not placed at the correct time in the correct way, facilities see major product loss of material per missed bag.
To replace the manual process, a robotic depalletiser can transfer bags — even loose, unstrapped bundles — from the pallet to the automatic bag placer. Automated bag application systems eliminate provide steady packing by ensuring continuous and accurate bag placement. Then, the bag placer securely places the bags onto the filling spout at a rate that matches the packing machine, with an output of up to 6,000 bags per hour with some models. An automated bag application system allows for a consistent, sustained pace for bag placement that is simply impossible to achieve with manual labour.
Some plants are limited by space, making it difficult or seemingly impossible to accommodate the footprint needed for production-boosting automation. This requirement previously inhibited automation, forcing manual placement and increasing safety risks by putting operators near the packing machine. However, innovative new products developed by leading manufacturers provide systems to transfer empty bags from the bag applicator to the packing machine, eliminating the need to place the bulky applicator right next to the packing machine. With the new and innovative systems, bag applicators can be positioned away from the packing machine — even in a different room. Not only does this protect the bag applicator from the immediate surroundings of the packing machine, but it also allows the plant to position it in a way that makes maintenance easier and allows users to completely rethink their empty bag logistics process.
Properly maintained equipment works more efficiently for longer, increasing sustainability and allowing operations to get the most out of their packing line. In addition to these options, palletisers — either robotic or traditional layer palletisers — can be incorporated to completely automate lines from empty to full bag.

Digitalisation and lifetime of equipment
The integration of equipment monitoring technology across all machines is an excellent way to achieve easier equipment optimisation and preventative maintenance tailored to the needs of the plant. Maintenance warnings or optimisation adjustments are displayed on the HMI, which is integrated into the control and weighing units of the machine, allowing service personnel to address concerns before they become critical and preventing unexpected downtime and lost production.
Systems with a centralised digital solution connect multiple machines together to translate data from the machine control and weighing system, making updating the entire packing line easier and resulting in more versatility. These systems require relatively low investments and result in fast return on investment. One of the easiest ways to start a sustainability journey is to invest in digitalisation.
Beyond digitalisation, some manufacturers offer rebuilds and upgrades kits to expand the flexibility, longevity and return on investment of packing lines. These kits also help the plant adapt as changes are made to the composition of materials. Many kits come preconfigured, making connecting them much easier than other upgrade options. As businesses continue to grow, some plants will need to expand, whether that means diversifying into other materials or adding new locations.

ETO approach
While many quality assemble-to-order systems enhance key sustainability metrics, operations that want to take things one step farther often look to packing plants that are truly engineered to order. For facilities seeking even more tailored solutions, engineer-to-order (ETO) systems offer long-term benefits by allowing companies to customise with all the features that continue to save money and boost profitability for years to come. Consider working with a manufacturer that offers a truly consultative approach to determine the best options for not only the packing machine but the entire plant.
All together, these systems make packing powdered material safer, cleaner and more efficient, allowing for greater operational sustainability. Choosing the right technology is an essential step to maximise the sustainability process when it comes to preventing product loss and saving resources like energy.

Diversification and expansion
In the cement industry, circumstances change quickly, and operations need options to meet demand wherever in the world that might be. Look for a manufacturer who offers prefabricated, modular packing systems for quick installation in situations with short timelines between when a purchasing decision needs to be made and entry into a new market. These specialised systems can be disassembled and reassembled in different areas, making it a sustainable option for production facilities.
It has also become increasingly important for operations to look for ways to diversify their product output. One way cement plants can do this is by using cement byproducts to create new materials. For example, instead of burning limestone, plants can use it as a component of fertiliser, which allows for an additional source of revenue in new
markets and effectively reduces the amount of CO2 the plant produces. To accomplish this, consider working with a manufacturer that offers a depth of expertise in a wide range of industries and process engineering capabilities.

Our blue planet
No matter what the future of packing brings, when experienced cement producers and equipment manufacturers partner, it results in more sustainable, efficient plants. The future of sustainability does not just rely solely on reducing power usage, dust suppression or even minimising product loss. Instead, the truly sustainable operations will be those that account for the big-picture view of all factors — from environmental to social and economic.

About the author:
Frank Ormeloh, Business Unit Manager for Cement, HAVER & BOECKER, is a mechanical engineer with over 30 years of industry expertise.

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Concrete

The Collaborative Revolution

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2 months ago

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August 5, 2025

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Dijam Panigrahi, Co-founder and COO, GridRaster, discusses how AI, digital twins and cobots are reshaping cement manufacturing.

The modern industrial landscape in cement production is changing, driven by the convergence of artificial intelligence (AI), digital twins and collaborative robots (cobots). This trifecta is not only enhancing existing operations but fundamentally reimagining how cement manufacturing functions, creating a synergistic environment where human and machine capabilities are maximised.
The International Federation of Robotics (IFR) notes that the global operational stock of industrial robots reached 4.2 million units in 2023, with cobots accounting for a considerable share. Furthermore, the global collaborative robot (Cobot) sales market, valued at $1,020 million in 2024, is projected to reach $2,199 million by 2031, growing at a compound annual growth rate of 11.8 per cent during the forecast period of 2025-2031.
At the heart of this evolution is AI, serving as the intelligent core that orchestrates a multitude of processes in cement production. Its capabilities span from optimising cobot control and predictive maintenance for kilns and grinding mills to ensuring stringent quality control of cement mixtures and streamlining complex supply chain management of raw materials like limestone, clay and gypsum.
AI empowers machines and robots with the ability to learn, adapt, and make real-time decisions, leading to significant improvements in operational efficiency and responsiveness across the board in cement plants. This intelligent automation is enabling the cement industry to achieve levels of precision and speed previously unattainable.

Digital twins: Virtual replicas for real-world optimisation
Complementing AI’s computational prowess are digital twins, which offer virtual replicas of physical assets and processes within a cement plant. These digital models provide an invaluable sandbox for businesses, allowing them to simulate and rigorously test new systems and workflows in a virtual environment before committing to costly physical implementation, such as optimising a new production line or a material handling system.
This capability is particularly crucial for optimising human-robot collaboration, as it allows for the fine-tuning of interactions and processes to ensure seamless integration and maximum output in potentially hazardous areas of a cement facility. The real-time monitoring capabilities of digital twins further enhance their utility, enabling continuous optimisation and proactive problem-solving, for example, by predicting equipment failure in a kiln. The synergy between AI and digital twins significantly reduces risks associated with new deployments and accelerates their time to market.

Empowering the human workforce: Upskilling and collaboration
While the focus on advanced automation might suggest a diminishing role for human workers, the reality is quite the opposite in cement manufacturing. Workforce enablement technologies are designed to empower and elevate the human element within this increasingly automated ecosystem.
These innovative tools facilitate comprehensive upskilling through immersive augmented reality (AR) and virtual reality (VR) training programmes, preparing the workforce for the demands of new technologies and roles, such as operating and maintaining cobots or analysing digital twin data. User-friendly interfaces are simplifying human-robot interaction, making it more intuitive and accessible for workers to collaborate directly with cobots in areas like quality control or material handling.
Furthermore, remote assistance capabilities provide on-demand expert support, ensuring that human workers have the resources they need to troubleshoot and optimise operations effectively in a cement plant.

A synergistic future: Boosting productivity, flexibility and safety
One of the most significant advantages of integrating cobots in cement manufacturing is their ability to offload repetitive, dangerous or physically demanding tasks from human workers, such as bagging cement, loading trucks, or operating in dusty environments. This frees up the human workforce to concentrate on higher-value activities that
demand critical thinking, problem-solving, and creativity – uniquely human attributes that machines cannot replicate.
This integrated approach not only drives remarkable gains in productivity, flexibility and safety but also cultivates a truly synergistic relationship between cutting-edge technology and a skilled, adaptable human workforce.
The implications of this integrated approach extend across various facets of cement manufacturing. The precision and speed offered by AI-powered cobots, validated through digital twin simulations, lead to reduced errors in mixing, faster production cycles, and greater customisation capabilities for different cement types. This translates into higher quality products and the ability to respond more rapidly to market demands.
The optimisation of supply chains through AI and the efficient handling of raw materials and finished goods by cobots result in faster delivery times, reduced operational costs and enhanced inventory management in cement plants. The ability to simulate and optimise complex logistical networks with digital twins means that potential bottlenecks in material flow can be identified and resolved before they impact real-world operations, leading to a more resilient and responsive supply chain for cement.
Moreover, the emphasis on workforce enablement ensures that as technology advances, human workers are not left behind but rather become integral components of the new industrial paradigm in cement production. Upskilling initiatives, facilitated by AR/VR, allow for continuous learning and adaptation, creating a dynamic workforce capable of navigating technological shifts.
The simplified human-robot interfaces remove barriers to entry, making collaborative robotics accessible to a broader range of workers in
cement facilities. This human-centric approach to automation fosters a more engaged and empowered workforce, leading to increased job satisfaction and reduced turnover.
The combination of AI, digital twins and cobots today represents a fundamental modernisation of the cement manufacturing landscape. AI provides the intelligence, digital twins offer the foresight and cobots provide the physical execution, all while workforce enablement technologies ensure that humans remain at the center of innovation and decision-making in cement plants. This integrated approach promises a future where operations are more efficient, resilient and adaptive, ultimately leading to unprecedented levels of productivity and a more fulfilling work environment for all in the cement industry.

About the author:
Dijam Panigrahi is Co-Founder and COO of Gridraster with over 21 years of international experience in market development, business growth, and product management.

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