Enhancing reliability and efficiency across cement production

Maximizing Cement Plant Reliability: Solutions for Optimal Performance

The cement industry operates under extreme mechanical stress, high temperatures, and continuous production demands. In such harsh conditions, equipment reliability is essential for operational efficiency, safety, and energy optimization.

With cutting-edge condition monitoring solutions, Acoem empowers cement manufacturers to anticipate failures, extend asset lifespan, and minimize costly downtime across Raw Mills, Vertical Roller Mills (VRM), Kilns, Roller Presses, and Cement Mills.

Cement Reliability

of total production costs are related to maintenance activities.

maintenance cost reduction achieved through predictive monitoring.

0K$

Approximate cost avoided by shutting down a separator in a cement plant with a capacity of 5,000 tons per day.

Maximize uptime and ensure production continuity

Acoem’s advanced monitoring technologies deliver continuous insights into the health of critical machinery, allowing proactive maintenance strategies that boost efficiency and reliability.

Real-time monitoring of mills, kilns, and crushers – Detect early-stage wear, imbalance, or misalignment with AI-powered diagnostics.
Predictive maintenance for heavy-duty assets – Optimize maintenance schedules, avoid unplanned downtime, and extend equipment lifespan.
Wireless and online solutions – Simple deployment and continuous data transmission, even in dusty, hot, or inaccessible environments.

Discover how SCG improved plant reliability with Acoem’s MVX and Accurex AI solutions

Critical Areas Requiring Condition Monitoring

Raw Mill & Vertical Roller Mill (VRM)

1. Raw Mill & Vertical Roller Mill (VRM)

Subject to variable loads, low rotational speeds, and heavy vibrations. MV-x systems monitor planetary gearboxes and bearings in real time, providing early fault detection despite process noise and variable speed.

Roller Press

2. Roller Press

With slow turning and high compression forces, roller presses are prone to bearing failures. MV-x + Oil Temperature & Quality Sensors ensure precise vibration and process data correlation, detecting issues early.

Kiln

4. Kiln

Operating at only 2–3 rpm, kilns require structure and bearing monitoring. MV-x + Creep and Crank Sensors detect shell deformation, misalignment, and rolling tire issues before they become critical.

Cement Mill

3. Cement Mill

Variable load, shocks, and large gearboxes demand constant supervision. MV-x and Falcon portable systems provide a full picture of asset health for optimal maintenance scheduling.

Why choose Acoem for cement reliability?

Over 50 years of expertise in condition monitoring for cement, mining, and heavy industries.
Integrated ecosystem – All in One (portable, wireless, online): NEST Vision unites vibration, oil, temperature, and process data into a single diagnostic view, combining all Acoem technologies for total reliability management.
AI-driven analytics (Accurex AI) for instant, expert-validated insights and auto-diagnosis.
Smart Anomaly Detection & Shock Finder™ for faster fault identification and predictive intervention.
Proven results – Up to 30 % maintenance savings and near-zero unplanned shutdowns.

Tailored solutions for cement industry challenges

Complex, slow-speed machinery

1. Complex, slow-speed machinery

VRMs and kilns rotate at extremely low speeds (2–18 rpm), making fault detection difficult. Acoem’s high-resolution sensors and long-time waveform analysis provide accurate insight into slow-turning components.

Harsh and dusty environments

2. Harsh and dusty environments

Acoem’s MVX and Eagle wireless sensors are designed for high-vibration, ATEX, and dust-heavy areas, ensuring reliability even in extreme heat or abrasive conditions.

Variable load and process shocks

4. Variable load and process shocks

Reduce unnecessary interventions by up tCement processes generate unpredictable load variations and vibrations. Acoem’s enveloping techniques and signal conditioning isolate mechanical faults from process noise. o 30% by focusing on critical repairs identified early.

Accessibility challenges

3. Accessibility challenges

Wireless monitoring and remote diagnostics reduce the need for on-site presence, keeping maintenance teams safe and productive.

Real-time insights for better decisions

With Acoem, every data source works together seamlessly — giving you continuous, actionable insights across your entire operation. Our fully unified ecosystem ensures that whatever the asset, the measurement method, or the environment, everything flows into one intelligent platform: NEST.

Unified Data Ecosystem — Portable, wireless, online all converge in NEST for a complete, real-time overview of machine health.
Embedded AI Intelligence — Accurex™ AI operates directly within the ecosystem to detect faults early, predict failures, and prioritize the most critical actions.
Integrated Field-to-Cloud Workflow — From portable measurements to continuous monitoring, every inspection and every sensor feeds a single source of truth.
Expert-Enabled Decision Support — Remote diagnostics, centralized history, and built-in advisor tools help reliability teams act faster and with greater confidence.

Acoem’s ecosystem turns fragmented measurements into a coherent, predictive reliability strategy, enabling smarter decisions and stronger operational performance — in real time.

Discover how proactive maintenance transforms cement vertical roller mill reliability in India

Acoem — Your Partner in Cement Reliability

Up to 30 % reduction in maintenance costs.

Through early fault detection and optimized maintenance planning.

Extended equipment lifespan by 20 %.

By maintaining assets under ideal operating conditions.

Quick ROI (<3 months) on predictive monitoring systems.

Achieved through reduced downtime and smarter resource allocation.

Advanced laser alignment for cement applications

Precision alignment is essential for high-load rotating equipment such as mills, fans, and kilns. Proper alignment reduces vibration, minimizes wear, and increases energy efficiency across the entire production line.

Discover the success story about how precision alignment enhances cement drum mill performance in Senegal

Acoem offers laser alignment tools for every need :

AT-200

The smart app-based shaft alignment solution

Discover

AT-300

Next-generation digital line laser system redefining precision and productivity in measuring methods.

Discover

AT-400

Achieve precision with the Acoem AT-400 high-end dual-axis shaft alignment system.

Discover

Shaft alignment tools

Discover

Detect and Correct Unbalance Issues with the Acoem Wireless Balancer

Unbalance in critical assets like large combustion blowers or rolling mill motors can lead to excessive wear, energy loss, and costly downtime.
The Acoem Wireless Balancer enables fast, precise on-site balancing before unbalance impacts your machinery.
Using advanced vibration and balancing algorithms, it identifies the source and severity of unbalance, guiding you through corrective actions to restore smooth, efficient operation

Learn more about the Acoem Wireless Balancer

Advisor Turnkey Services

Gain actionable insights from Acoem’s global support network. Our certified experts provide real-time recommendations, enabling faster, more informed maintenance decisions.

Remote diagnostics 24/7 from Acoem’s global centers.
Automatic expert reports in NEST Vision, with alerts for detected anomalies.
Process-aware diagnostics — our analysts correlate vibration, process parameters, and operating conditions to deliver deeper, context-driven insights impossible to obtain from vibration data alone.

Discover Advisor