Solutions by industry / Cement
Closed-loop AI on the cement mill, +10% yield
A global cement producer automated one of its mills with Wizata, then scaled the same solution to 5 more mills, on time, on budget and with ROI within a year.
The challenge
Maximum feed rate, without stressing the mill
As part of a digital transformation to increase revenue, the producer wanted to maximise the mill feed rate while keeping mechanical conditions stable and the risk of equipment stress low.
Manual adjustment was too slow and inconsistent for the mill's dynamic behaviour:
What the team set out to do
- Recommend the best combination of three critical set points, continuously, as conditions change.
- Improve efficiency by more than 10% and reduce energy consumption.
- Reduce production downtime.
- Train local teams to maintain, manage and evolve the system.
Our approach
From clean history to a fully automated mill
Wizata worked with the plant's process engineers to build a data-driven closed-loop automation system.
Clean data, valid clusters
Historical data was cleaned of unstable operating periods. Models then identified the valid operating clusters of set-point combinations.
Real-time set points, early warnings
Models recommend the most effective parameters for current conditions and detect mechanical anomalies in the hydraulic and lubrication systems before failure.
Closed loop, one dashboard
The full system runs in closed loop. Operators see status, recommendations and alerts on a real-time dashboard.
The outcome
More yield, fewer stops, now on six mills
With better process consistency and stability, and less downtime. ROI within a year.
Closed-loop optimisation
Set points applied automatically, with less operator intervention.
Early anomaly detection
Hydraulic and lubrication issues caught before costly mechanical failures.
Scaled to 5 more mills
Replicated across plant locations, confirming the solution is robust.
Local teams in control
Wizata trained the producer's teams to maintain, manage and evolve the system.
Case study
Download the cement case study
The full story on one page: the mill, the models, the results.
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