Proactive Maintenance Transforms Cement Vertical Roller Mill Reliability in India

Customer: A leading cement manufacturer

Application: Cement Industry

Location: India

EXECUTIVE SUMMARY

A leading cement manufacturer in India faced challenges in monitoring and maintaining over ten vertical roller mills critical to production. By implementing Acoem’s MV-x system with Machine Condition Tracking (MCT) and Acoem Advisor, the company achieved proactive maintenance, reduced downtime, and improved equipment reliability.

The Challenge

The customer’s vertical roller mills were vital to continuous production. Traditional maintenance methods made it difficult to detect early signs of mechanical issues, leading to:

Unplanned downtime and production losses
Increased maintenance costs due to reactive interventions
Risk of severe equipment damage if faults went unnoticed

The inability to monitor machine health in real-time limited their ability to plan maintenance efficiently, putting both operations and profitability at risk.

The Solution

The customer implemented the following Acoem Reliability solutions:

MV-x system for continuous vibration monitoring
Machine Condition Tracking (MCT) integrating process inputs
Diagnostics software for in-depth fault analysis
Acoem Advisor for automated reporting and actionable recommendations

The customer selected Acoem Reliability for its proven expertise in industrial machinery monitoring, comprehensive diagnostic capabilities, and user-friendly reporting tools that directly addressed their specific operational challenges.

How it addressed their needs:

Enabled real-time monitoring of over ten vertical roller mills
Provided early detection of bearing, gear, and other mechanical issues
Allowed predictive maintenance scheduling, reducing reactive interventions

The Results

Early detection of equipment faults, preventing major failures
Significant reduction in unplanned downtime across all monitored mills
Optimised maintenance planning based on actual machine condition
Increased confidence in equipment reliability and production continuity

The Impact

Beyond immediate operational improvements, the Acoem solution:

Strengthened the customer’s trust in predictive maintenance technology
Fostered a long-term partnership between Acoem Reliability and the customer
Enabled the company to plan capital expenditure more effectively, as machine health data informs future investments