Autonomous lime kilns, 50 kilns on several continents

A global lime producer automated its kilns with Wizata: set points driven by data, anomalies caught early, and the same system replicated across its sites.

Talk to an engineer See how it works

50 kilnsrunning autonomously with limited human intervention

+10%top-quality lime

6× fasterroot-cause analysis on process machinery

Industry

LimeKilns

Focus

StabilityQualityEnergyAvailability

With Wizata

Set-point automationAnomaly detectionMachine learning

The challenge

From fixed formulas to kilns that decide

The producer wanted to automate its kilns in plants across several locations and run daily operations on insights from production data.

Its control relied on empirical and mathematical formulas that could not adapt to changing conditions:

Rigid empirical controlUnstable processEnergy and quality lossesUnplanned stoppages

What the team set out to do

Use smart systems that support, and then execute, autonomous decisions.
Automate set points from data to stabilise the process and maximise energy and quality efficiency.
Anticipate failures, so maintenance targets only misbehaving equipment.
Build one system that scales and replicates across global sites.

Our approach

Cloud data, learned control, instant alerts

The producer and Wizata built the system together, then rolled it out kiln by kiln.

1Consolidate

One cloud architecture

All existing data processing moved to a cloud-based architecture, for scale and access to every data source.

2Control

Learned set points

Data exploration and machine learning found the variables that drive stability. Control algorithms keep the target quality and a stable kiln.

3Protect

Anomaly detection

Operations teams are alerted instantly, so they can restore full capacity and efficiency before a stoppage.

Components of the AI solution

40% 30% 20% 10%

40% deterministic and expert control 30% set-point recommendation models 20% anomaly detection 10% temperature forecast models

The outcome

A stable process, better lime, fewer stops

Unsold inferior quality −70%

Quality stabilised around optimal targets, with 10% more top-quality lime.

−3% solid fuel

Lower overall energy consumption from a more stable process.

+10% top quality

Quality held around its optimal targets.

6× faster root cause

Problems on process machinery are diagnosed six times faster.

Fewer sudden stops

Failures are predicted, and asset reliability improves for the long term.

Built on the Wizata platform

Explore the platform →

Data HubEvery kiln as a digital twin, on one cloud architecture across sites.

AI LabSet-point, temperature-forecast and anomaly models, replicated to 50 kilns.

Control PanelAutonomous control with instant alerts for operations teams.

Next step

Let your kilns run themselves

You don't have to do it alone. Talk to one of our engineers, or spend one or two days with our team on your own data.

Talk to an engineer Book a free assessment

Your contact Martina Zanetti mza@wizata.com +34 603 791 220