Cement industry is a capital extensive industry with high fixed and operational costs. In these turbulent times it is vital to focus on operational efficiencies to ensure sustainable profitability. Sensys offers solutions in various domains for all processes starting from HMI/SCADA to advanced manufacturing systems utilizing the real-time data to increase productivity and efficiency and minimize downtime. Our experience is unmatched, with the track record for providing state of the art vertical solutions to cement plants locally and worldwide.


Operator Level/Centralized HMI

Sensys provides state of the art customized high resolution representation of plant floor and processes specific to cement industry ensuring visibility and traceability of the entire operations in a plant and enabling the management to perform monitoring and control on real-time basis. We provide Centralized Monitoring and Control of Crusher, Raw-Mill, Preheater, Cooler, Cement Mills and Packing. We offer operator level console as well as act as a centralized platform in case of multiple facilities thus catering to entire needs of the company.

Plant Information Management System

Sensys offers state of the art Plant Information Management System with advanced historian capabilities that allows data collection, data storage, data archiving and instant data retrieval upon user request. Cement manufacturing comprise several processes such as Crushing, Grinding, Pyroprocesseing, Blending, Cooling, Finish Milling and Packing which lead to a large number of parameters and KPIs to be calculated and controlled. IntelliMAX enables clients to centralize data from various data sources and provides a central platform to access historical data. User can perform advanced trending and charting analysis on critical parameters for the processes such as such as Kcal/Kg, kwh/ton, feed rate etc.  Reports can be generated on KPIs such as Tons of cement/MJ, fuel substitution rate (%) and Net CO2 per ton of cement. Thus data can be used to perform in-depth analysis on both processes and operations to get better insights and improve productivity and efficiency.

Production Planning and Scheduling

Production Planning and scheduling is that critical phase from where the process of production at the shopfloor starts. Careful planning of production according to the orders and then its scheduling in order for smooth execution are critical for any cement plant. IntelliMAX facilitates the planning and scheduling of Cement and then tracks its execution in light of the original plan and schedule. This tight integration between planning and executions keeps all the stake holders in loop while the manufacturing on shop floor is in progress. At any point in time, the users can find out whether the production is going according to the plan or not. Automatic notifications are sent to the relevant stakeholders whenever the production deficit beyond a user defined threshold occurs between the planned and actual execution. Whenever there is any occurence of an un scheduled event, IntelliMAX automatically adjusts the plan for the remaining days and gives the projection of possible production according to the remaining scheduled days. Reasons for all those events that affect the production are recorded and also reported back to the ERP system.

Condition Based Maintenance

Condition based maintenance is a maintenance strategy used to improve the effectiveness of maintenance programs and reduce the life cycle costs of assets. It plays a key role in the capital extensive Cement Industry where the goal is to maximize production and minimize downtime. IntelliMAX caters to Condition based maintenance utilizing the real-time data associated with different assets such as Running hours, Temperature, Pressure, Vibration, Speed, Flow-rate, Voltage, Current, Stress, etc. and analyzing these to determine the state of assets. These parameters are regularly monitored on real-time basis and the values of the mentioned parameters are compared against their set points to see deviations. Trends can be plotted to analyze the behavior and thus predict the maintenance.

Energy Management

Cement is a capital intensive industry with high energy consumption and instrumentation across entire plant. Sensys provides cement and clinker plants with specific Energy dashboards in order to enable users to take necessary measures to optimize energy. IntellIMAX EMI provides visibility to system by providing real-time monitoring and control of energy parameters such as energy per ton of cement/clinker, energy utilized in different process such as Crushing, Grinding, Pyroprocesseing, Blending, Cooling, Finish Milling and Packing etc.  It has the capability to provide in-depth analysis via advanced trending, charting and reporting on Energy Consumption by source be it Water, Gas, Steam or Electricity. By having an accurate data about energy consumption, user can better estimate patterns and perform in-depth analysis to optimize the supply and demand for energy. We offer load balancing and optimization taking into account the demand in real-time. This results in secure and reliable energy availability, improved energy efficiency and better profitability.

Overall Equipment Effectiveness

SENSYS’s state of the art IntelliMAX EMI solution provides a comprehensive way to monitor and improve the overall efficiency of production processes through its OEE module. IntelliMAX EMI tracks key metrics contributing to OEE i.e. Availability and Performance since quality is assumed to be constant in this case. It provides users contextual analysis at Equipment, Assembly, Facility and Plant level. IntelliMAX EMI’s OEE dashboard enables users to analyze Planned vs. Actual OEE, Visibility of key reasons causing downtime, Analysis on Types of Losses and Knowledge of reasons attributing to performance loss. Personnel can perform advanced analysis on factors such as Kiln Downtime, Raw-Mill downtime etc. This results in better utilization of the assets and production lines which improves productivity and profitability.

Distributed Intelligence

Cement industry is characterized by large holding companies that own multiple plants geographically distributed at different/remote locations. Sensys distributed intelligence solution serves the need by providing an open, secure and scalable centralized platform ensuring lossless integration and hence reliability. IntelliMAX has the capability to act as a local server at each individual site providing real-time monitoring and control at plant level and at the same time act as a central server placed at head office providing complete real-time information of all the facilities at one location. It also has the ability to integrate with the business applications such as SAP, Oracle etc. thus fully utilizing the potential of real-time data using it effectively to take timely decisions.

Central Enterprise Portal

The cement industry is characterized by a number of processes and in such context, the need for a centralized platform becomes inevitable for better coordination among different functions and better utilization of resources. Sensys provides a state of the art Central Enterprise Portal that facilitates knowledge transfer and provide enterprise wide visibility. It allows a single platform for different business and process applications so that better collaboration can take place and decisions be taken timely and accurately.