Cement

More good clinker from the kiln you already run.

In a cement plant, efficiency is decided by how steadily the kiln burns, how much heat and power go into every tonne, and how many hours the kiln and the mills actually run between stops.

Book a site survey See how it works

Our first deployments are with auto-component makers. In this industry we start the same way, with a site survey on your floor and a written read-out of where we would begin.

Where efficiency is lost

Four places a cement plant loses efficiency.

Stamped builds models of your plant from the data it already records, finds where efficiency is lost across process, quality, planning and maintenance, and improves it with actions your team can take.

01 · Process and controlLearn more »
Run the kiln better than its best days.
Most kiln losses come from instability rather than a broken machine: raw-meal chemistry swinging between shifts, false air creeping in at a seal, a coal feeder pulsing, or a burning zone that one crew runs hotter than another. Stamped models how each kiln line behaves and recommends feed, fuel, draught or cooler settings that improve on your steadiest days, for your process engineer to accept, adjust or turn down.
EnergyHeat per kilo of clinker and power per tonne of cement are counted on every recommendation.
02 · Quality and lot checksLearn more »
Catch a free-lime excursion before it fills a silo.
Free lime and fineness come back from the lab hours after the conditions that caused them. Stamped links lab results to the kiln and mill conditions that came before them, so when the kiln starts behaving the way it did before the last high free-lime results the shift in-charge hears about it in time to correct it, and each grade's record is ready when a customer asks.
EnergyOverburning to stay safe on free lime costs fuel, so a controlled band saves both.
03 · Planning and schedulingLearn more »
Plan mills, grades and dispatch together.
Mill run plans, grade changes, power availability and silo levels are usually juggled in spreadsheets, and an unplanned kiln stop throws all of them out at once. Stamped keeps track of the whole plant, from kiln and mill status to silo levels, power availability and dispatch, and when something changes it proposes the mill and dispatch sequence that works best across all of it, showing what each option does to output, power cost and silo position.
EnergyRunning mills in cheaper power windows is treated as one input to the plan, alongside output and dispatch.
04 · MaintenanceLearn more »
Prescribe the fix that saves the most clinker.
Kiln stops from refractory hot spots, fan vibration, cooler problems or mill trips each cost hours of output and a heat-up. Stamped ranks stops by the clinker and cement they cost, watches specific energy consumption and other slow drift, such as shell temperature creeping up in one zone or a fan drawing more power for the same flow, and prescribes the fix and a window that fits the kiln and mill plan, so maintenance knows where to look first and when.
EnergyEvery unplanned stop is another heat-up, so fewer stops also means less fuel.

In this plant

Raw mill, kiln and cooler, cement mills and utilities.

A cement plant records a great deal already, from the control room and the lab to the electrical system and the dispatch yard, but those records rarely get looked at together.

Crushing and raw mill
Kiln stability starts with the raw meal, so Stamped follows how quarry and stockpile changes show up in raw-mix chemistry and in raw-mill throughput, and flags the shifts where the kiln is likely to be fed something harder to burn.
Kiln and cooler
In the pyro section the questions are about heat per kilo of clinker, free lime, back-end oxygen and kiln availability, and Stamped compares each shift with the line's steadiest days so the process engineer can see which setting moved and what it cost.
Cement mills
Grinding is the largest electrical load in most plants, and mill output and power per tonne move with fresh feed, separator speed and fineness targets, so Stamped ranks each mill against its own best weeks on the same grade.
Fans, compressed air and waste heat recovery
Fans, compressors and the waste heat recovery system sit on the power bill whether clinker is moving or not, and Stamped points out the ones running harder than the line needs and the drift that usually comes before a trip.

Example actions

What the people who own the problem receive

Each action goes to the person best placed to act, with what to do, by when, and the reasoning behind it.

Process

Kiln, for the process engineer

Back-end oxygen has run above its usual band for [N] hours, which on this line usually means false air at the inlet seal, so a seal check and a small draught correction are ready for review.

Quality

Kiln, for the shift in-charge

Kiln conditions over the last [N] hours look like the run before last week's high free-lime results, so an extra clinker sample this shift would show early whether the burning zone needs attention.

Energy

Cement mill, for the mill in-charge

Mill 2 is using more power per tonne than in its best week on the same grade and fineness, and separator speed is the main difference, so a new setting is ready for your review.

Planning

Planning, for the planner

Kiln 1 is expected to be down for about [N] hours, and the proposed mill and dispatch plan keeps today's trucks on time using clinker already in the silo.

Maintenance

Kiln, for the maintenance lead

Shell temperature in zone 3 has crept up by about [N]°C over the past few days, which is worth checking against the last refractory survey before it becomes a hot spot.

Maintenance

Fans, for the electrical lead

The ID fan is drawing more power for the same flow than it did a month ago, so the impeller and dampers are worth inspecting at the next stop.

These are examples, and numbers in [brackets] are placeholders. Your pilot writes the real ones from your own plant data.

Impact

What changes in the plant.

The first finding usually comes within about two weeks. Results are measured against your own baseline and published only with your permission.

Fewer rejections reach the customer

Because lots at risk are caught in real time, while they can still be saved.

More output from the same lines

With bottlenecks, idle time and restarts found and fixed, and control improved beyond your best runs.

Fewer surprise breakdowns

Since slow drift shows up in data you already collect.

Less energy for every good part

Once idle heat, reheats and scrap are counted and brought down.

Before you book

What owners usually ask us first.

Book a site survey

What does it cost?: Only the pilot price is agreed at the survey. The pilot is paid and priced on its own, and the annual price comes after, based on the pilot's results.
What do we need to install?: Nothing new to start. Stamped connects to the machines, meters, ERP and registers you already have, and the survey tells you plainly if that is enough.
How much of my team's time?: Some hours with your plant head and your quality and maintenance leads during the survey, planned around production. In the pilot, actions reach the people who already own that work.
Is our data safe?: We sign an NDA before the survey. Stamped runs on a zero-trust architecture with encryption, your data is stored on cloud servers in India, and we work only with the data your team agrees to share.

Book a site survey

FAQ

Common questions

Has Stamped worked with cement plants?

Our first deployments are with auto-component makers. In cement we start the same way, with a site survey on your floor and a written read-out of where we would begin, and we publish results only with a plant's written permission.

Does Stamped replace our kiln control or expert system?

No. Stamped works alongside the control systems you already run and sends its recommendations to your team. Stamped recommends and your team decides.

Do we need new hardware, or another system next to MES, ERP and SCADA?

No hardware retrofit is needed to get started, because Stamped is software that works with the systems you already run. It is not another MES or CMMS: your MES, ERP and SCADA are where the data comes from, and Stamped works alongside them. Stamped brings their data onto one timeline, so they finally work as one picture of the plant.

How do we start?

We start with a site survey, which means a few days on your floor and a written read-out of where efficiency is being lost and what we would change first. If it makes sense, that is followed by a paid pilot on one line for eight to twelve weeks, and the first finding usually comes within about two weeks.

More good clinker from the kiln you already run.

Four places a cement plant loses efficiency.

Run the kiln better than its best days.

Catch a free-lime excursion before it fills a silo.

Plan mills, grades and dispatch together.

Prescribe the fix that saves the most clinker.