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§ Industry · 11

Cement plants: kiln to finish mill, monitored.

Cement plants depend on rotary kilns, raw mills, and finish mills that combine heavy-duty mechanical loads with high-temperature process exposure. Droz applies vibration analysis, thermography, and laser alignment across the line — from raw materials to packaging. Reference client: Holcim.

Request a plant-wide program → Capabilities
Asset focus
Kiln · Raw mill · Finish mill
Key disciplines
Vibration · Thermography · Alignment
Standards
ASME · ISO 10816
Reference client
Holcim
§ Operating context

Why downtime is brutal here.

Cement plants are continuous-process operations where every line stop equals tonnes of unrecovered clinker.

  • Kiln criticality. The rotary kiln is the single most expensive asset; an unplanned kiln stop cascades through the entire plant.
  • Grinding-circuit wear. Raw-mill and finish-mill liners, grinding media, and bearings are heavy consumables that benefit from trended condition data.
  • Refractory cycles. Brick wear inside the kiln dictates shutdown timing; vibration trends help defend the shutdown date.
  • Energy intensity. Cement is among the world's most electricity-intensive industries; mis-aligned drive trains compound cost.
§ Disciplines

Disciplines we apply.

DSC · 01

Vibration analysis

Kiln drives, raw / finish mills, ID fans, conveyor drives.
DSC · 02

Thermography

Switchgear, transformer surveys, kiln-shell scans.
DSC · 03

Ultrasound

Bearing lubrication; compressed-air leak surveys.
DSC · 04

Laser alignment

Large-bore drive trains, fan-train alignment.
§ Assets addressed

Assets we monitor.

DZ-A · Rotating equipment

Kiln-line rotating fleet

Kilns · mills · fans

  • Rotary kilnsTrended
  • Raw & finish millsTrended
  • Vertical millsTrended
  • ID & kiln-feed fans · conveyorsTrended
DZ-B · Static equipment

Process boundaries

Preheater · coolers · HX

  • Preheater towersInsp.
  • Clinker coolersInsp.
  • Heat exchangersInsp.
  • Piping systemsNDT
DZ-C · Electrical & controls

MV switchyard

Switchgear · MV transformers

  • Switchgear LV/MV/HVIR scan
  • MCCsIR scan
  • MV transformersIR scan
  • PLCs · SCADAIntegrated
DZ-D · Production lines

Cement-line stages

Raw-meal · kiln · finish · pack

  • Raw-meal preparationTrained
  • Kiln lineTrained
  • Finish grindingTrained
  • PackingTrained
§ Standards

Standards we operate under.

ASME
Pressure-vessel & mechanical
ISO 10816
Vibration severity
Vibration Institute
Cat. I–IV
CMVA
Canadian machinery vibration
§ Software layer

Software services for this industry.

SW · 01

AI & Machine Learning Systems

Kiln-stability pattern recognition; mill load forecasting.
SW · 02

Reliability Data Platform

Multi-plant condition history with refractory-cycle annotation.
SW · 03

Cloud Migration & Architecture

Fleet-wide data ingestion across plants and grinding stations.
§ Engagements

Case studies.

CS · 01

Engagement case studies forthcoming

Holcim engagement summary will be published once cleared by marketing. Anonymized program outcomes appear in the case-studies index.

CS · 02

More engagements →

Browse the case-studies index for anonymized engagement summaries across other industrial sectors.
§ Plant-wide engagement
Plant-wide reliability program · Request engagement.
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