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Explore Cabisol

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CABISOL | Cement Industry

From Concept to performance

CABISOL delivers integrated automation, electrification, and end-to-end execution support for cement plants to stabilize kiln operations, improve clinker and cement quality, and reduce energy intensity across the plant.

Integrated Solutions for Cement Excellence

Scope includes engineered panels, instrumentation, electrical distribution and substation interfaces, plus season/asset-aligned services. Industry 4.2-aligned digital governance and analytics are implemented as required to drive reliability, compliance and decarbonization outcomes.

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Quality

Clinker/cement consistency

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Energy
Lower kWh/t and heat rate

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Emissions

CO2 reduction readiness

Common Pain Points in Cement Operations

  • Driven by aging controls, weak instrumentation and inconsistent operating discipline

  • Thermal + electrical across kiln, mills, fans and material handling

  • Due to limited diagnostics, spares strategy and readiness governance

  • Fragmented vendor responsibility across E&A&I packages.

  • For quality, energy intensity, reliability and emissions-reduction tracking

Our Solutions

Outcome-led programs engineered to improve throughput, extraction efficiency, quality consistency, and energy performance across steel, aluminum, and mining operations.

    • EPC projects for unit upgrades and balance-of-plant modernization

    • PMC for multi-contractor execution and outage governance

    • Detailed engineering (E/A/I/M) for power, controls, and instrumentation

    • Installation & commissioning with cutover planning and SAT/FAT discipline

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    • Kiln & Cooler Control Modernization

          Stability + quality

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    • Raw Mill and Finish Mill Control
      Standardization

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    • IoT Integration
      Plant-wide visibility (implemented as required)

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    • Digital Solutions
      KPI governance, event analytics

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    • AI Optimization
      Process setpoint optimization, where applicable

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    • Digital Twin
      What-if simulations and operator enablement, where applicable

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    • Cybersecurity
      OT hardening and monitoring

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    • Remote Monitoring​​

           Expert support and faster troubleshooting

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    • Operation & Maintenance Model

           Asset-aligned

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    • AMC

          Season/production-aligned coverage

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    • Breakdown Maintenance

           Rapid restoration

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    • Troubleshooting

          Root cause + recurrence prevention

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    • Calibration & Testing

           I&C + protection verification

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    • Spare Parts Strategy

           Critical spares governance

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    • Training

           Operators + maintenance

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    • Inspection & Audits

          Reliability, safety, compliance

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    • Health Checks

          Controls, drives, panels, networks

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    • Energy Audits

           kWh/t and heat rate improvement roadmap

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    • Decarbonization Solutions

           Baseline, tracking and phased roadmap

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    • Green Energy Solutions (integration support as required)

     

    • Energy Recovery & Efficiency (WHR integration readiness and efficiency packs)

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Our Products

Products deployed across the plant. Digital platforms and analytics are covered under Digital Solutions.

    • PLC control systems (controllers, remote I/O, panels, configuration)

    • DCS systems (controllers, I/O hardware, operator panels, integration)

    • SCADA and HMI (operator stations, servers, panels, configuration)

    • Industrial networking (OT-ready switches, gateways, integration as required)

  • 1. Treatment & compliance applications

    • Flue Gas Treatment – instrumentation + analyzer integration for emissions control systems

    • Wastewater Treatment (ETP/STP/WWTP) – online monitoring and control instrumentation

    • Arsenic Treatment – monitoring instrumentation and analyzer packages (as per process requirement)

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    2. Core process instrumentation

    • Flow Instruments

    • Level Instruments

    • Pressure Instruments

    • Temperature Instruments

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    3. Analyzer & emissions monitoring

    • Gas Analyzers (e.g., O2 / CO / NOx, where applicable)

    • Dust / Particulate Monitoring (where applicable)

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    4. Plant control & measurement packages

    • Weighing / Feeding Instrumentation (where applicable)

    • Valve Positioners and Control Elements (actuators, I/P converters, control valves, accessories)

    • AC drives (LV/MV, panels, configuration)

    • DC drives (where required)

    • Soft starters (with panels and integration)

    • MCC panels (operation and control integration)

    • Substation equipment (as required)

    • MV switchgear (HT panels and operation)

    • LV panels (LT distribution and control)

    • Transformers (power and distribution)

    • Cables and wires

    • Protection relays and metering (configuration and integration)

    • LV motors

    • HV motors

    • Synchronous motors

    • Generators

    • Excitation/AVR and synchronization equipment

Our Support 

1.  Commissioning and cutover governance for brownfield upgrades

2.  Calibration Discipline and protection
verification to reduce repeat trips

3. Breakdown Response and troubleshooting model(production-aligned)

4.  Readiness Governance for shutdowns, start ups and performance stabilization

5.  Spare Parts Strategy with critical spares prioritization

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Our Process Expertise

  • Quarrying and crushing (where applicable)

  • Raw material handling and raw mill

  • Preheater / precalciner (where applicable)

  • Rotary kiln and clinker cooler

  • Clinker handling and storage

  • Finish grinding (cement mills)

  • Packing, palletizing and dispatch

  • Utilities (compressed air, water, fans, blowers)

  • Electrical substation, distribution and protection coordination

Digital Solutions

Digital governance and analytics that convert operations data into performance actions.

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Plant-IQ 360

Plant-IQ 360 (implemented as required): KPI dashboards for availability, heat rate, and asset health

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Remote Monitoring

Remote monitoring and support workflows for incident response

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Industrial IoT Integration

Industrial IoT integration to connect DCS/PLC, drives, meters, and analyzers

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AI Optimization

AI optimization for combustion stability and auxiliary efficiency (as applicable)

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OT Cybersecurity

OT cybersecurity solutions for hardening, monitoring, and access governance

Case Studies & Clients

  • Cement modernization and reliability programs (available on request)

  • Energy intensity reduction and optimization programs (available on request)

  • Commissioning governance and brownfield cutover delivery (available on request)

Case Studies

View Case Studies
Request a Reference Call

Some of our esteemed clients

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HOLCIM CEMENT

GUATEMALA

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MANASEER CEMENT

JORDANIA

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SILVERMILL GROUP

SRI LANKA

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FUJAIRAH CEMENT INDUSTRIES

DUBAI

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JK LAKSHMI CEMENT LTD

INDIA

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ULTRATECH CEMENT LTD

INDIA

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HOLTEC CONSULTING PRIVATE LIMITED

INDIA

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Concept to Commissioning

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