Digitalization in the Cement Industry: Holcim Aleșd Implements Predictive Maintenance with AI and Machine Learning

Schneider Electric Romania and Holcim Romania are taking a significant step in digitalizing the cement industry by implementing an advanced predictive maintenance program for the electric motors at Holcim’s Aleșd plant. The project leverages artificial intelligence and machine learning algorithms to prevent critical failures and optimize the performance of industrial installations.

“Electric motors are the heart of any industrial facility, and at Holcim Aleșd, they support a production flow that is essential for the local economy. Through this project, we have not only prevented critical failures but also redefined how maintenance is carried out in the industry,” said Lucian Enaru, General Manager of Schneider Electric Romania, Moldova, and Armenia. “AI and Machine Learning technologies allow us to act proactively, before problems occur, protecting operational continuity and ensuring client performance.”

Technology and Collaboration for Performance

Schneider Electric currently monitors nine medium- and low-voltage electric motors at the Holcim Aleșd plant using Motor Current Signature Analysis (MCSA) technology. This system captures data directly from the power panel without prolonged equipment downtime, providing a precise view of the motors’ condition. The collected data is processed in Microsoft Azure cloud and analyzed by Schneider Electric experts at the regional hub in Novi Sad, who interpret the signals and provide recommendations for preventive maintenance.

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“Collaboration with the Holcim team and our specialists was essential to the success of this project. The 90% validation rate of the alerts confirms the solution’s efficiency and the real impact on client operations,” added Lucian Enaru.

This initiative is part of a broader partnership between Schneider Electric and Holcim Romania, established under an international agreement in 2021. Implementing predictive maintenance increases equipment safety and reliability, optimizes maintenance costs, and provides an innovative perspective on how technology supports industrial production.

By adopting intelligent digital solutions, Holcim and Schneider Electric demonstrate that innovation and sustainability can go hand in hand, supporting both industrial performance and the economic development of the local community.

Photo: holcim.com