Titan America successfully implemented digitalization applications based on artificial intelligence and machine learning at its cement plants in Roanoke, Va., and Medley, Fla., resulting in significant operational improvements, cost efficiencies, and solid performance.
The producer deployed autonomous AI real-time optimization algorithms that dynamically process vast amounts of data from plant sensors and continuously adjust variables, bringing the equipment to optimum operational performance. With each iteration, the AI algorithms rapidly maximize throughput and decrease energy consumption in all the main assets of the plants.
Further elevating the reliability of its plant operations, Titan has implemented plant-wide failure prediction systems that continuously receive and analyze signals from thousands of sensors to detect process and equipment operation abnormalities significantly earlier than could be otherwise detectable. The alerts generated are reviewed and evaluated by dedicated teams in remote service centers, staffed by deep domain experts.
The experts analyze each event to determine potential root causes, identify corresponding corrective actions, and collaborate with plant operators to troubleshoot issues at the earliest stages, allowing intervention well before breakdowns occur.
Finally, AI-based predictive quality applications, supported by sophisticated quality control equipment, are being implemented to predict cement performance at the time of production, enabling plant operators to improve the grinding process, lower clinker consumption, and ensure consistent product quality and performance resulting in less carbon footprint.
“I’m incredibly proud to mark the end-to-end digital transformation of our cement plants. A systematic process of test and learn that started several years ago has reached an important milestone,” said Titan America President and CEO Bill Zarkalis. “Titan America is today at the forefront within our Industry. But we know this race is a marathon, a continuous process of reimagining and redesigning the way we produce and offer our products and solutions to meet the fast-changing market and community needs. As we continue to build digital capabilities within our manufacturing, logistics and customer-care processes, we remain focused on our mission to offer innovative construction materials and solutions that improve life on our planet.”
Capitalizing on the gains realized from the digitalization of its manufacturing process, Titan America is now moving to boost the overall customer experience through the deployment of similar digital and predictive application solutions to optimize its logistics and distribution systems. These enhancements will result in a more resilient, efficient and predictable supply chain with improved bottom-line results.