TRANSFORMING CEMENT PLANT
MAINTENANCE & ENVIRONMENT.
Predictive maintenance for rotating equipment + automated baghouse monitoring on one platform. RotaryIQ keeps your kiln, mills, and conveyors online. DustIQ keeps you EPA-defensible. McKinsey-benchmarked 10–20% maintenance cost savings.
Cement & Mining — baghouse air quality + rotating equipment + worker safety, all on one backbone.
BAGHOUSE · KILN · MILL · CONVEYOR.
RELIABILITY IS THE KEY TO A SUCCESSFUL FUTURE.
In today's competitive and highly regulated cement industry, optimizing maintenance and minimizing environmental impact is critical for operational excellence and profitability. Unexpected equipment failures lead to costly downtime — and stricter emissions regulations put constant pressure on dust and particulate control.
BEFORE & AFTER SENZARIZATION.
The typical cement plant: quarry → crusher → blender → grinder → raw mill → preheater → rotary kiln → cooler → cement mill → packing. Every stage has rotating equipment, dust, and waste. Every stage benefits from continuous sensing.
Rotary Kiln
Vibration on drive train, ring gear, kiln shell rollers. Thermal stress monitoring. Predict bearing failures weeks before catastrophic stoppage.
Raw & Cement Mills
Vibration + acoustic on ball mills. Trunnion bearings, gearboxes, motors. Mill load monitoring via current and acoustic signature analysis.
Preheater Towers
Differential pressure across cyclones. Coating detection. Refractory hotspot monitoring via thermal imaging integration.
Electrostatic Precipitators & Baghouses
Continuous dP. Stack opacity. Particulate matter monitoring. EPA-defensible audit trail. Real-time bag failure detection — catches issues hours before visible emissions.
Conveyors & Bucket Elevators
Belt slip monitoring. Roller bearing health. Vibration sensors on every drive pulley. Catches misalignment, gearbox wear, lubrication breakdown.
Cooler & Packaging
Fan health, motor health, packing-line throughput. Cooler grate plate temperature distribution. Stop overheating before clinker quality drops.
THREE AREAS TO ADDRESS.
Processes
We help customers assess their goals, identify reliability gaps in current operations, and implement corrective actions and strategies to keep operations running smoothly.
People
Reliability is about more than tools and processes — it's a company-wide effort that touches operations, maintenance, logistics, planning, scheduling, purchasing. Senzary supports the change.
Tools
Everything needed: sensors, continuous monitoring, wireless sensor systems, portable data collectors, analyzers — combined in a unified predictive asset maintenance platform.
IAC ENGINEERING + CLARIOS TOLEDO.
100+ baghouse systems deployed across IAC Engineering cement and aggregate networks. 400+ sensors collecting data 24/7. Customer savings exceed $2M to date. At Clarios Toledo, 14 sensors monitor oxide-room rotating equipment + baghouses on the same IoTLogIQ platform.
RotaryIQ + DustIQ.
Start with one baghouse and one rotating asset group. 90-day pilot. Pays back on the first avoided failure or prevented emissions event.