Revolutionizing Cement Manufacturing with our Comprehensive IIoT Platform

Deploy Facttwin solutions, to equip your cement plant with real-time data insights and advanced analytics for enhanced efficiency and compliance.

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Preferred by leading organizations in transforming their real-time
manufacturing data into actionable insights

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Key Challenges in the
Cement Industry

01

Poor Energy Conservation

To deal with optimizing energy consumption, cement manufacturers utilize plants across diverse processes such as kilns, mills, and clinkers to minimize expenditure and comply with environmental regulations.

02

Lack of Product Quality

Achieving uniform product quality from raw material grinding to cement milling calls cement industry operators for accurate quality control and monitoring throughout the operational processes.

03

Failure to Meet Environmental Regulations

In order to adhere to strict environmental laws and regulations, cement manufacturers identify opportunities for emission reductions that necessitate real-time monitoring and proactive management.

04

Reduced Operational Efficiency

Complex manufacturing processes with optimized resource utilization require cement industry operators to leverage maximum production efficiency while reducing downtime.

Enabling Reliable Production
in the Cement Plant Operations

Facttwin effortlessly scales your operations to manage a hundreds of gateways,
while delivering industry-leading performance throughout diverse environments.

Continuous Monitoring of Critical Equipment

Continuous Monitoring of Critical Equipment

Facttwin connect provides real-time, high-fidelity data to key cement production machines such as crushers, kilns, and mills for maintaining a solid control over material composition that ensures optimal performance.

Dynamic Quality Management

Dynamic Quality Management

Facttwin Intelligence offers real-time visibility into plant floor operations and utilizes actionable insights into raw meal composition, kiln control, and mill performance to improve product quality and throughput.

Intelligence-based Decision Making

By harnessing the power of data analytics, Facttwin empowers cement manufacturers to access manufacturing data into a single platform, thereby predicting potential issues before any occurrence of unplanned downtime.

Sustainable Environmental Compliance

Sustainable Environmental Compliance

Due to its high emissions and resource-intensive nature, Facttwin helps cement-specific plants to monitor energy consumption, clinker factor, emission levels, and production efficiency in real-time, facilitating compliance with sustainability goals.

Refine your complex operations
in the Cement Industry

Enable seamless data acquisition from various machines, sensors, and control systems
in the cement production process, and get actionable insights into critical manufacturing processes.

Real-time monitoring for optimal performance

Right from optimizing process conditions, use Facttwin Connect to enable real-time monitoring and optimization

  • Ensure consistent particle size with crushers and millers
  • Monitor key parameters like temperature, pressure, and material flow
  • Optimized cooling process for energy consumption
  • Acquire data from mills to produce the final product

Streamline your Cement Manufacturing Process

Apart from monitoring individual assets, Facttwin Intelligence ensures smooth operations across all stages

  • Optimal mix of raw materials assured
  • Identify opportunities to improve clinker quality
  • Increase throughput by optimizing cement grinding process
  • Integrate data from analyzers and control systems

Achieve operational excellence in real-time

Enable proactive management for making informed decisions by tracking KPIs in real-time

  • Reduce cost with specific energy consumption
  • Track the ratio of clinker to cement produced
  • Monitor emissions from the kiln to be compliant with environmental regulations
  • Optimize asset utilization by tracking the actual production rate

Advance your Digital Cement Plants with Facttwin

Our Facttwin solutions empower real-time data for enhanced productivity

  • Acquire real-time data from various systems
  • Integrate data into unified platform
  • Predictive insights using advanced algorithms
  • Visualization tools for decision-making
  • Notifications for proactive issue identification & resolution

Begin your journey towards
operational excellence with Facttwin

Take the first step towards data-driven excellence

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Frequently Asked Questions

What are the main challenges faced by the cement industry?

The cement industry is one of the largest producers of greenhouse gases, accounting for 7% of global carbon emissions. Other challenges include land acquisition and logistics issues as these processes can be time-consuming and expensive.

How can Facttwin help improve energy efficiency in the cement industry?

Facttwin empowers cement manufacturers to achieve optimum usage of energy by significantly reducing its operational cost. It provides granular visibility into energy consumption, optimizes kiln operations, and leverages alternate fuels and raw materials (AFR) in order to maximize energy efficiency.

What is the role of technology in the cement industry?

For the development of greener, smarter low carbon cement solution, technology plays an integral part in the cement industry. Nowadays, the cement industry is shifting towards Industry 4.0 by implementing cutting-edge technologies like Big Data, Industrial IoT, Artificial Intelligence (AI) to enhance sustainability, efficiency, and productivity.

How does Facttwin support sustainability in the cement industry?

Facttwin offers comprehensive Industrial IoT solutions to reduce waste and increase resource efficiency in cement manufacturing environments. By implementing eco-conscious production processes, Facttwin helps cement manufacturers to foster long-term economic viability by achieving a zero-waste commitment to the environment.

What are the benefits of using Facttwin for quality control in cement production?

Facttwin enables cement manufacturers in continuous monitoring of critical parameters to meet the quality specifications in the cement production cycle. Facttwin Health provides predictive maintenance solutions to identify the underlying issues and facilitates corrective actions for product excellence.

How can Facttwin enhance supply chain management in the cement industry?

Facttwin gives a holistic view of the entire supply chain by integrating data across the manufacturing plant. This allows cement manufacturers to monitor and track production processes and distribution, enabling informed decisions and reducing delays.

What are the key trends in the cement industry?

Cement industries are increasingly adopting key trends like low-carbon cement production and use of alternative materials thereby meeting the rising demand for environmentally friendly products. Additionally, digitization and automation in cement plants allows for better resource management and waste reduction.

How does Facttwin help with regulatory compliance in the cement industry?

Facttwin provides tools for emission monitoring and reporting to maintain safety standards and regulatory compliance. Moreover, Facttwin platform sends alerts to the manufacturers on abnormal conditions, ensuring that the operations stay within the regulatory limits and reducing the risk of hefty penalties.

What role does data analytics play in the cement industry?

Data analytics helps cement manufacturers by leveraging real-time actionable insights to analyze energy consumption and performance indicators. This enables them to create predictive maintenance solutions, improve quality control, and integrate with legacy systems, thus increasing efficiency, profitability, and competitiveness.

Can Facttwin assist with predictive maintenance in the cement industry?

Yes, Facttwin offers predictive maintenance solutions that can anticipate equipment failures, minimize unplanned downtime, and reduce maintenance costs.

Still have questions?

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