SENTRADO
中

Cement & Building Materials Automation

CEMAT-based process automation for cement plants — from raw material crushing to clinker production and finish grinding.

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CEMAT — The Cement Industry Standard

The cement industry faces accelerating challenges: rapid urbanization, tightening environmental regulations, rising energy costs, and increasing demand for product traceability. SENTRADO delivers comprehensive automation solutions based on the Siemens CEMAT process control system, covering the entire cement production chain.

Our solutions span the complete production process: limestone crushing → raw mill → preheater → rotary kiln → clinker cooler → cement mill → packaging. With CEMAT's cement-specific process library and integrated engineering environment, we deliver faster commissioning, standardized operations, and optimized performance.

30+
Years CEMAT Use
8%
Capacity Boost
5%
Heat Savings

Production Process Coverage

  • Limestone crushing & raw material handling
  • Raw material grinding (vertical mill / ball mill)
  • Preheater & precalciner tower
  • Rotary kiln & burner management
  • Clinker cooler & conveyor systems
  • Cement milling, blending & packing

Core Solutions

End-to-end automation and digitalization solutions for every stage of cement production.

CEMAT Process Control

Siemens CEMAT-based integrated process control system covering the entire cement production process with industry-specific function blocks.

Unified engineering & operation platform
Pre-configured cement process library
Standardized multi-plant deployment
Lifecycle support: design to maintenance

Rotary Kiln Control

Automatic control of kiln temperature, speed, and feed rate. APC advanced process control for optimal clinker burning.

Burning zone temperature optimization
Kiln speed & feed rate coordination
APC model predictive control
Fuel & alternative fuel management

Raw Mill & Cement Mill Control

Automatic mill load adjustment to maximize throughput while minimizing energy consumption per ton.

Mill load auto-regulation
Particle size monitoring
Separator speed optimization
Specific energy minimization

Energy Management System

Real-time monitoring of electrical and fuel consumption with kiln thermal efficiency optimization.

Power consumption per ton tracking
Kiln heat consumption analysis
Fan VFD energy optimization
Carbon emission reporting

Equipment Predictive Maintenance

Online vibration and temperature monitoring with fault early warning to reduce unplanned shutdowns.

Vibration & temperature monitoring
Bearing degradation detection
Fan & motor health analytics
Maintenance planning integration

Digital Consulting

Whole-plant digitalization planning, maturity assessment, roadmap development, and investment optimization.

Digital maturity assessment
Strategic roadmap planning
Risk mitigation & rational investment
Continuous improvement program

Technical Specifications

Industry-proven hardware and software platforms for cement plant automation.

Core System

Siemens CEMAT process control system built on SIMATIC PCS 7 platform for cement-specific applications.

SIMATIC PCS 7CEMAT

PLC Controllers

High-performance Siemens PLC platforms with redundant CPU options for critical process areas.

S7-1500S7-400

Drives

SINAMICS variable frequency drives for kiln drive, mill motors, and large fan speed control.

SINAMICS S120SINAMICS G120

HMI

CEMAT operator stations with cement-specific faceplates and standardized visualization.

WinCCCEMAT Operator Station

Communication

Industrial fieldbus networks for real-time data exchange between controllers, drives, and field instruments.

PROFINETPROFIBUS DP

APC

Advanced process control using model predictive control for kiln and mill optimization.

SIMATIC PCS 7 APC

Reference Projects

Proven track record in cement plant automation across the globe.

Heidelberg Cement

Using CEMAT for over 30 years with standardized deployment across multiple plants globally. CEMAT serves as the unified automation platform for all production lines.

5,000 t/d Clinker Line

Full-plant CEMAT automation with APC optimization. Achieved 8% capacity increase and 5% thermal energy reduction through intelligent kiln and mill control.

Cement Plant Energy Retrofit

Fan VFD retrofit combined with energy management system. Annual electricity savings of 2 million kWh with ROI achieved in under 18 months.

Frequently Asked Questions

Common questions about our cement plant automation solutions.

What advantages does CEMAT have over traditional DCS?
CEMAT is purpose-built for cement and building materials production. Unlike generic DCS systems, CEMAT includes pre-configured process library blocks for kilns, mills, coolers, and separators. It offers integrated HMI, batch management, and APC in a single platform — reducing engineering time by up to 80% compared to traditional DCS programming. Heidelberg Cement has used CEMAT for over 30 years as their global automation standard.
Can you upgrade automation for existing cement plants?
Yes, we specialize in both greenfield and brownfield cement plant automation. Our retrofit solutions include migrating legacy DCS/PLC systems to CEMAT, upgrading HMI and operator stations, adding APC optimization, installing new instrumentation, and integrating energy management — all with minimal production disruption during planned shutdowns.
How much benefit can APC advanced process control deliver?
APC typically delivers 5-10% throughput increase, 3-8% reduction in specific energy consumption, and improved product quality consistency. In our reference projects, a 5000 t/d clinker line achieved 8% capacity increase and 5% heat consumption reduction after APC deployment. The ROI is typically achieved within 6-12 months.
How does predictive maintenance reduce downtime?
Our EPA (Equipment Predictive Analytics) system continuously monitors vibration, temperature, and other critical parameters on key equipment such as kiln drives, roller mills, and large fans. By detecting early-stage bearing defects, misalignment, and lubrication issues, we can schedule maintenance during planned stops rather than emergency breakdowns — reducing unplanned downtime by 30-50%.
Do you provide full EPC services for cement plants?
We provide comprehensive automation and electrical scope within EPC projects, including engineering design, procurement, programming, FAT/SAT, installation supervision, commissioning, and training. While we don't handle civil works or mechanical installation, our automation scope covers the complete control system from field instruments to the central control room. We also offer digital consulting for plant-wide master planning.

Discuss Your Cement Plant Project

Whether you're building a new cement production line or upgrading existing automation systems, our engineering team is ready to help. Get a customized solution proposal for your project.

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