Technology
Technology for alternative fuel firing
Published
4 years agoon
By
admin
Use of low-grade alternative fuels such as waste coal, tyres, sewage sludge, and biomass fuels (such as wood products, agricultural waste, etc.) in pre-calciners is a feasible option since combustion in pre-calciner takes place at a lower temperature.
India is the second largest cement producer in the world and accounted for over 8 per cent of the global installed capacity as of 2019 with an overall cement production capacity of around 545 MT in FY20. The Indian cement industry is swiftly developing due to the increasing demand of construction sectors, be it housing, commercial, industrial, etc.
Cement manufacturing being a high energy consuming and heavy polluting process accounts for at least 8 per cent of the total emission of greenhouse gases. At the same time, energy-related expenses in the cement sector, mostly on fossil fuels and electricity, account for 30 to 40 per cent of the industry?? cash costs.
Historically, the primary fuel used in cement industry is coal. Recent increases of coal prices in the Indian market again made the cement industry vulnerable to fuel cost. Since then, petroleum coke has been successfully used as fuel and the use alternative fuels in cement kilns is now common and increasing. Although fossil fuels such as coal, petroleum, natural gas, etc. can provide all the energy the world needs for the time being, their finite nature, high prices and most importantly, their damaging effect on the environment underscore the need to develop alternative fuels.
Today?? cement industry becomes more challenging for the following main factors: the lowest production cost and minimum environmental impact. Beyond the cost-reduction benefits of alternative fuels, use of these fuels can contribute greatly to the environmentally sound disposal of waste and to the mitigation of greenhouse-gas emissions (GHG). Therefore, key cement players have started to consider alternative fuels as a lever to improve their contribution to sustainable development and as a key component of corporate social responsibility.
This is certainly a win-win option for both cement industry and the society at large. There is, hence, an urgent need to implement appropriate policies and practices in favor of co-processing in the country so that it can contribute reasonably towards the waste management needs of the country and help industry in substituting alternative resources in the cement manufacturing process. This would require substantial capacity building in the relevant stakeholder community ??particularly the policy makers, authorities, waste generators, facility providers and the cement plants.
Alternative Fuel options available
The range of alternative fuels is extremely wide. Use of low-grade alternative fuels such as waste coal, tyres, sewage sludge, and biomass fuels (such as wood products, agricultural waste, etc.) in pre-calciners is a feasible option since combustion in pre-calciner takes place at a lower temperature. The major Alternative Fuel available to use in India would be MSW (Municipal Solid Waste).
Sewage sludge: In several countries, sewage sludge is used in cement production. The sludge is usually co-fired with coal in pre-dried form. Pre-dried sludge is easier to store, transport and feed. However, it has a high content of SiO2, Al2O3 and Fe2O3 which could affect the quality of cement if excess amounts are used.
Used Tyres: Combustion of whole tyres requires long residence times to obtain complete conversion. In some cement installations, tyres are fired whole, mostly in the rotary kiln. More commonly, they are shredded in a slashing process, producing tyre chunks or chips, and co-fired with coal in the precalciner. They cannot, however, be finely comminuted economically. FLSmidth offers HOTDISC? Combustion Device for high efficient firing of used tyres.
Agricultural Biomass- A largely untapped renewable energy source: The type of biomass utilized by cement plants is highly variable, and is based on the crops that are locally grown/available. For e.g., rice husk, hazelnut shells, coconut husks, corn stover, coffee pods, and palm nut shells are among the many varieties of biomass currently being burned in cement kilns. Biomass fuels are considered carbon neutral because the carbon released during combustion is taken out of the atmosphere by the species during the growth phase.
Major challenges of using agricultural biomass residues include the relatively low calorific value which can cause flame instability, and availability since most of the agricultural residues are seasonal (not available all year round). The flame instability problems could be overcome with lower substitution rates and ability to adjust air flow and flame shape.
Other major Alternative Fuels include waste oil, liquid waste, Plastic, Meat and bone meal, etc.
Benefits of using Alternative Fuels in Cement Production
Cement producers are striving to lower their production costs. One effective method of achieving this end is the use of alternative fuels.
The reduction in emissions to the atmosphere and the positive environmental impact it holds is a major benefit of Alternative Fuel firing. In pre-calciners where kiln exhaust gases pass through, the NOx emissions are much reduced due to reburn reactions. Also, there is an increased net global reduction in CO2 emissions when waste is combusted in the cement kiln systems as opposed to dedicated incinerators, resulting a reduction in penalties.
Key considerations and challenges for co-processing Alternative Fuels
The potential benefits of burning alternative fuels at cement plants are numerous. However, the contrary is possible where poor planning results in higher emissions or when they are not put to their best use with best practices.
Alternative fuels used in cement manufacturing have different characteristics compared to the conventional fuels. Switching fuels present several challenges that must be addressed in-order to achieve successful application. The type of fuel used can introduce some material components which can interfere with the chemistry of the cement materials as well as affect the operation of the system. The use of a type of fuel is hence subject to the constraints imposed by any effect on cement quality, refractory life, gas and material flow or potential emissions to the atmosphere.
Poor heat distribution, unstable pre-calciner operation, blockages in the preheater cyclones, build-ups in the kiln riser ducts, higher emissions and dusty kilns are some of the major challenges.
FLSmidth Alternative Fuel Firing Technology
Introducing alternative fuels has an impact across the plant. The materials can have totally different characteristics from fossil fuels. They can be sticky, fluffy, moist, and fluctuating in size and quality or you may need to switch between different types of fuel with very different characteristic due to governed by availability. They will burn differently, have a different reaction in the kiln and may require you to take other actions to ensure consistent clinker quality. There are a lot of variables at play ??which is why you need an experienced partner on your side.
With over 25 years of direct alternative fuels experience and more than 130 years in the cement industry, FLSmidth? offers a range of products to enable Cement Manufacturers to increase their substitution of Alternative Fuels.
JETFLEX? Burner
Cement kilns have several characteristics which make them ideal installations for disposal of waste through co-processing in an environmentally sound manner:
– High temperatures
– Long residence time
– Oxidizing atmosphere
– High thermal inertia
– Alkaline environment
– Ash retention in clinker
FLSmidth?? JETFLEX? Burner is a highly flexible kiln burner, designed to produce the best flame shape and lowest NOx emissions for various fuel types and operating conditions. It fires rotary kilns with pulverized coal or coke, oil, natural gas, or any mixture of these fuels. Alternative fuel firing of plastic chips, wood chips and sewage sludge can also occur through the same common fuel channel to improve heat and power consumption and minimize cold airflow entering from the fuel transport.
JETFLEX? PLUS Burner
For optimum combustion flexibility, our JETFLEX PLUS Burner offers superior combustion of cost-effective grade fuels, complete flame-forming control and increased fuel retention time. The two design features that characterize the JETFLEX PLUS Burner model are individually rotatable jet air nozzles and a retractable center pipe for alternative fuel firing.
The individual rotatable nozzles also enable fuel lift configuration. This is used with solid alternative fuels to increase fuel retention time in the flame. The result is less fuel drop-out, improved combustion, and improved clinker quality. The swirler is the main mechanism for shaping the flame during start-up and daily operation.
The JETFLEX PLUS burner offers retraction of the swirler and central duct. In combination with the axial air nozzles, this enables a significant drop in fuel velocity in front of the burner. This feature strongly increases the fuel retention time in the flame and enables early ignition of low grade fuels. In combination with the fuel lift configuration as noted above, spillage to the charge is minimised. This allows the burner to contribute to superior flame and clinker quality control as well as a high alternative fuel substitution.
HOTDISC? Combustion Device
The HOTDISC solution allows cement producers to substitute coal or other fossil fuels with a wide range of alternative fuels. The HOTDISC is a flagship solution for FLSmidth?? MissionZero that helps cement producers take an important step toward zero-emission cement plants by 2030. Launched in 2004 and over 35 installations worldwide, the HOTDISC Combustion Devices has already firmly established itself as an attractive technology to accelerate cement plants??transition toward alternative fuels.
From wet powders to solid waste up to 1.2 metres in diameter, our HOTDISC Combustion Device can burn them all. The waste to energy process eliminates the need for expensive shredding and gives you the flexibility to select the most economical choice from a wide range of alternative fuel options. The HOTDISC Combustion Device is designed to achieve a calciner fuel substitution rate of up to 80%, although results vary significantly depending on specific plant conditions.
As an integrated part of your kiln system, the HOTDISC Combustion Device is added onto the calciner and functions as a slow-moving disc furnace. When alternative fuel, preheated raw meal and tertiary air are fed into the HOTDISC, it produces combustion gases, partly calcined meal and combustion residues. These are then processed in the calciner alongside the other streams entering it. The result is calcined meal ready for the kiln and well-controlled emissions.
Alternative fuels are introduced onto the slowly rotating disc and they start to burn in fully-oxidising conditions when they meet the hot tertiary air. The burning fuel is transported approximately 270? on the disc until it reaches the scraper, where the remaining ash and partly calcined materials are discharged into the riser duct. Heavy combustion residues fall into the kiln inlet, while lighter fragments and combustion gases move up into the calciner.
HOTDISC-S? is a recently developed version of HOTDISC specifically to cater the needs of customers with SLC type calciners, hence enabling them to achieve Alternative Fuel firing. Two of these devices have been commissioned globally and running successfully.
Low NOx Calciner
With a goal to optimise production costs, FLSmidth?? Low NOx Calciner has been enhanced for operational stability, availability and combustion efficiency.
NOX regulations are continuously being tightened around the world. Meeting NOx emissions limits is therefore a key demand for cement producers, not only because NOx-related issues, such as smog pollution, have a direct impact on the local society, but also because your plant?? license to operate is directly linked to its NOx emissions.
Multiple fuel inlets are given to ensure optimal distribution between the kiln gases and the fuel. To achieve the best distribution between the kiln gases and the fuel, there are multiple inlets (four or six, depending on plant size). Better fuel distribution provides optimal mixing, which gives the highest average cross-sectional temperature without any build-up problems.
The Low NOX Calciner has the flexibility to burn almost any type of fuel. This includes traditional fuels, including coal and natural gas, more difficult-to-burn fuels, such as petcoke, and most solid and liquid waste fuels. These fuel types are burned while achieving low NOx and CO emissions.Primary Mitigation
Another simple solution FLSmidth? provides for reducing the NOx emissions in the existing plants is the Primary mitigation NOx reduction through calciner design changes. These are basically layout changes to create one firing location, one meal split, one air stream entering tangentially to the calciner and creating “hot zone??and ??eduction zone?? The plant system is studied and appropriate modifications are recommended. For even lower NOx emissions, FLSmidth? provides SNCR system as an add-on solution.
Kiln Gas By-pass System
Kiln gas bypass systems have traditionally only been used in regions where the local raw materials are naturally high in chloride, sulfur or alkalis. The growing use of alternative fuels and other materials is also increasing the input of chloride to kiln systems to the point that may require a bypass to maintain process stability or product quality. FLSmidth has extensive experience with the design and use of kiln bypass systems.
Main features:
– Quench chamber with dual layer dip tube
– Quench air inlet flap valve
– Control scheme for maximum stability
– Special lining design in transition pipe section
– Constant force support system
– Multiple layout possibilities
While the fundamental principles of a bypass system have not changed, state-of-the-art technology and design tools have been incorporated to improve bypass efficiency and maximise reliability. Most projects today will at least have the space for a future small chloride bypass (less than 10%) with respect to use of alternative fuels and materials.
Conclusion
The co-processing of waste as AFR disposes the waste completely and thereby eliminates the societal concerns associated with it. In Indian cement industry, if these initiatives could increase thermal substitution to the level of European countries, the cement industry can reduce its GHG emission by a significant amount, impacting the overall country?? GHG emission.
The type of fuel used in cement production is subject to the constraints imposed by its effects on cement quality, refractory life, emissions to the atmosphere, etc. and hence requires proper study and planning by specialists before implementation.
To reduce fuel cost in cement industry, globally, waste materials and low-grade fuels are co processed extensively as alternative fuels or energy sources. India still has a long way to go in ensuring greater substitution of AFRs, resulting in sizable conservation of natural materials and fossil fuels and to make the most out of the technology available for the same.
Author:
Gopika Krishnakumar
Product Line Manager
Cement Industry/Pyro Technology
FLSmidth
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Digital technologies are transforming safety
Published
2 months agoon
August 11, 2025By
admin
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.

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.

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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