Predictive Operation

Control your cement quality

Predict the product quality of your plant’s clinker and cement production – using AI and neural networks: Our solution IQCnet continuously and independently taps process and laboratory data to find the best operating conditions for your plant.

polab® Cal

Automated isothermal calorimeter

polab® Cal represents a quantum leap in quality and process control within the cement industry. For the first time ever, the reactivity of clinker and cement can be determined by a fully automated, isothermal calorimeter that can be integrated into laboratory automation systems. Previously, it used to take at least 24 hours to analyze the reactivity of clinker and cement. Now, the results are available in less than 60 minutes. We have achieved a breakthrough in digital process control and building-material development. polab® Cal offers users data for product and process control at an sofar unachieved level of precision, speed and repeatability.

polab® Cal is the first automated calorimetry system that can be fully integrated into polab® laboratory automation systems or used as a standalone unit in the fields of research & development or product development. The system prepares cement samples fully automatically and analyses them on the basis of parameters specified by the plant owner.

A model of the existing cement plant with all individual constraints forms the basis of the intelligent production planning. The self-learning sales forecast is calculated using historical values or can be entered manually if desired. The software then uses a mathematical model to determine the optimum production plan for following days, taking into account energy costs, production and storage capacities as well as the determined sales forecast – enabling significant reduction of operating costs.

Predictive Operation

Predict process behavior and
product quality in advance and in
dynamic operating conditions

Digital twin for what-if-analyses

Product quality
consistency

Forecast production &
demand

Benefits

Meeting new regulations for sustainability and avoiding emission fines is one of the biggest concerns and challenges of the cement industry, today. polab® Cal gives you full control over your clinker’s reactivity and puts you right behind the steering wheel when it comes to the clinker factor and emissions of your cement plant.

01.

Sample preparation

02.

Reactivity data available < 60 min

03.

Air-conditioned housing

04.

Data evaluation

Intelligent Production Planning

Custom production plans

Intelligent production planning is more than an algorithm that delivers data-driven production plans. What we offer is a comprehensive production planning service that includes self-learning sales forecasting, a user-friendly planning environment, and support from cement process specialists with on-site experience.

Benefits

Our fully automated Intelligent Production Planning Solution helps you to save resources and minimize productions costs significantly – making your plant not only smarter but more sustainable as well.

01.

Minimal investment

02.

Automation of production planning

03.

Reduction of operating costs

04.

Optimized production

News

Smarten up!

Our polysius® digital solutions offer easy to implement solutions to either make parts of your cement production smarter and more sustainable or go all the way and transform your entire plant to meet today’s regulations and remain competitive in the future. Which approach is most suitable for your cement plant?