Product development

LM Master: Optimising VRM

Published

4 years ago

October 14, 2021

admin

Vertical roller mills are often operated at lower capacities to safeguard the process against variables in feed characteristics. Using intelligent automation tools for mill control, operators can consistently obtain a good quality product while running the mill at its optimum capacity.

The kiln is at the heart of the cement manufacturing process and justifiably attracts most attention from plant operators. Grinding mills, on the other hand, are considered secondary and are not as frequently monitored as the kilns. Most of the time, the grinder is operated at less than its optimum capacity. This is done to get some margin for errors that may arise due to variations in mill process variables, for e.g., variations in feed material characteristics. Continuous monitoring and timely adjustments of the grinder feed can significantly impact overall productivity. An advanced vertical roller mill (VRM) controller from Loesche GmbH, helps operators to do just that.

Loesche (www.loesche.com) is one of the leading suppliers of roller mills for more than a century and caters to both the hardware and software needs of cement manufacturers. The company has been providing automation tools such as mill simulators and SCADA solutions to cement manufacturers. Recently, they have launched an advanced mill controller called LMmaster for VRM control. It is the standalone real-time process optimisation solution for an optimal operation of the Loesche grinding systems. The focus of the LMmaster is on efficient performance, increase mill throughput, ensure product consistency and increase plant availability. There is no additional engineering work necessary after the implementation of the solution.

Predictive control

The LMmaster applies Model Predictive Control (MPC), a specific mathematical model for imaging of dynamic processes with multiple interacting variables. With the model-based control, all PID-controllers are contained in one model so the process can be considered as a whole with respective influences of each variable. The LMmaster calculates the future state of the system and uses these values to define the new operaing points of each controller. For the calculation of operating points to the current set points, the current actual values, the disturbances as well as historical data are taken into account. This model calculates the new set points for the PLC, which are taken from the necessary control variables and outputs. This happens continuously and in real time to avoid any delays.

The system displays monitored variables and the current mill configuration continuously to improve operational visibility. The tool automatically initiates accurate control actions several times per minute and substantially increases mill performance.

The technology has an inherent capability for disturbance rejection. This feature is highly desirable in the grinding circuit control as the material hardness and nature of feed streams can vary rapidly and disturb the control circuit. The mill automatically adjusts its settings as per the changes in feed hardness, to promote consistent grinding.

System safety

The software is installed on a PC and it seamlessly integrates with the existing PLC system. The flexibility of setting-up detailed and accurate mill control models ensures that the in-house proprietary knowledge and intellectual property remains protected. The system allows multiple authorised users to access the system and monitor performance through a browser-based interface. Grinding mills have several components that can be damaged due to out- of -control vibrations. The LMmaster plays a key role in minimising these vibrations by calculating fresh set points several times a minute to maintain mill performance at very high levels. By specifying the overall – and competing – requirements for production rate, product consistency and energy consumption, the optimal combination of set points can be calculated on a high-frequency cycle to drive the process to the economic optimum continuously. The system is capable of taking corrective actions in time and hence, highly effective in preventing mechanical damage to the mill. Operators rarely get the opportunity to understand such problems in advance and reconfigure the mill parameters.

The LMmaster is valuable in such situations as not only does the mill operate at lower vibration levels, it also effectively reduces wear on gearboxes and other major components. Continuous online monitoring of the system reduces the likely hood of mill trip. The software applies Loesche’s expertise in mill design to run the mill to its maximum capacity without putting the machinery to any unnecessary mechanical stress.

Holistic control

In conventional PID systems, a single variable set point is compared to the controlled variable at regular time intervals. Different variables are monitored and are a part of separate control loops. In conventional systems, these loops remain disconnected with each other, leading to sub-optimal control. Accurate control and complete optimisation can be obtained only if the responses from the loop are integrated to work as a single system. The dynamically interrelated loops have to be fine- tuned to configure the entire system and achieve higher process efficiency.

Under stable conditions, the controller helps to increase production, while under conditions of stress, such as high vibration, the controller simultaneously acts to reduce vibration, protect process stability and restore production without compromising on product quality.

Conclusion

Mill performance can be significantly improved if process variables are looked at holistically and system configurations are changed dynamically to meet set objectives of the throughput. The system takes complete charge, running the mill to peak performance without compromising on product quality, while simultaneously lowering specific power consumption and vibration levels. The mill is consequently protected from mechanical stress which can lead to wear or damage gearboxes.

Case Study VRM optimisation for Nuh Cimento Sanayi

Founded in 1966, Nuh Cimento Sanayi, a Turkish cement company produces in-house quarry cement for the local Turkish market and for export. The high export quota has forced manufacturers towards more efficient production methods.

The plant manufacture uses conventional control technology and an efficient mill at a high level of raw meal for the subsequent production of cement. Nuh Cimento Sanayi’s goal was to increase the throughput of the mill with reduced energy use and increased availability of the system. The company decided to increase the plant efficiency by investing in a Loesche LMmaster . The solution was applied first to the raw material mill RM3, a vertical roller mill LM 63.4 with a capacity of 505 t/h and a specific power consumption of the main drives (mill motor, mill fan and classifier) of 15,8 kWh/t.

The results

The application at Nuh Cimento Sanayi in Hereke decreased specific energy consumption significantly. The plant now runs in a more stable and smoother fashion, with higher availability of the grinding system and reduced variation in product quality. SinceNuh Cimento owns the power plant on site, the reduction of the specific energy consumption is combined with reduced CO2 emissions.

"The LMmaster is taking over the grinding process and this gives our operators more time to concentrate on other processes," says Ismail Dogan, Clinker Production Engineer at Nuh Cimento Sanayi.

Key benefits realised

Rise in capacity of 5.8 % (29.4 t/h).
Reduction in specific power consumption of 4.95 % (0.78 kWh/t).
Improved consistency in operations.
Mill vibration reduced by 17.25 % (1.04 mm/s).
LMmaster controller utilisation greater than 90 %.
Substantial relief of the operator.

Since The LMmaster is installed on a separate industrial PC with its own software platform, there is no security threat to the installed control system. Another safety aspect is the switch back option that allows the operator to switch smoothly to the original PLC/DCS mode. Tellingly, the company never did switch back to the original PLC/DCS mode.

Key benefits of automating mill control

Improvement in production rates.
Better drying capacity via mill exit temperature control.
Low product size variability achieved by consistent grinding irrespective of variations in feed hardness.
Lower specific power consumption.
Improved mechanical stability and reduced vibrations.
Corrective actions taken on the fly to prevent damage to mill components and prevent a mill trip.

Economy & Market

Power Build’s Core Gear Series

Published

4 hours ago

February 19, 2026

admin

A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

Economy & Market

Conveyor belts are a vital link in the supply chain

Published

8 months ago

June 16, 2025

admin

Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

Economy & Market

Impactful Branding

Published

3 years ago

July 17, 2023

admin

Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.