Cement

In cement, the margin lives in the automation — not the architecture.

iCAM has delivered end-to-end electrical and automation systems across 10+ cement plants, including 7,000 I/O DCS systems and 100 MW TG synchronisation.

10+
Cement plants
7,000
I/Os — single plant
450+
Feeders — single MCC
The Challenge
01
Unplanned downtime is visible on the P&L.

Every unplanned kiln stoppage or grinding unit failure costs money in lost production. Plants with predictive automation run longer between failures.

02
Energy is the biggest controllable cost — and most plants don't control it.

Power consumption in cement is 60–70% of variable cost. Without EMS and PEMS, plants run on fixed schedules rather than real-time optimisation.

03
CPP complexity demands specialist control.

Load balancing, TG synchronisation, and import/export controllers at 60–100 MW require engineering depth that most automation vendors don't carry. iCAM does.

The Numbers That Matter
7,000
I/Os in a single plant
Siddhi Cement — ABB 800XA
450+
Feeders in a single MCC
Kanodia Cement — ABB UMC100
100 MW
TG synchronisation with grid
Jaypee Cement Karnataka CPP
Executed Projects
Delivered across India's leading cement manufacturers.
Siddhi Cement
ABB 800XA DCS for full cement plant — packaging plant Smart MCC (Siemens, ~50 feeders)
7,000 I/Os · 2,000 I/Os
Kanodia Cement — Amethi & Kaimoor
ABB 800XA DCS for grinding units — iMCC with ABB UMC100 (~450 feeders per plant), VFDs
1,500 I/Os · 450 feeders
Saurashtra Cement
Full plant DCS (ABB 500/AVEVA), EMS implementation, Silo extraction Smart MCC, SCADA
5,000 I/Os · EMS
RAMCO Cement
DCS (Schneider/AVEVA), SCADA modernisation — full plant controls upgrade
5,000 I/Os · Modernisation
Jaypee Cement — Karnataka
100 MW CPP — TG synchronisation with grid (Rockwell CLX), import/export control
100 MW CPP
Adani Cement
EMS implementation (Rockwell/AVEVA) — real-time energy optimisation and ESG reporting
EMS / ESG

Working on a cement plant project?

From DCS specification to CPP commissioning — talk to an iCAM engineer who has done it at scale.