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
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