What if you could increase production, reduce energy consumption and lower emissions without major investments, plant modifications or production shutdowns? Chinfon Cement, a Vietnamese cement producer, did just that by installing ECS/ProcessExpert® (PXP) 9.2 with Self-Adaptive Control.
Fuller Technologies’ ECS/ProcessExpert® (PXP) 9.2 with Self-Adaptive Control works as an intelligent autopilot alongside the operator, continuously optimising process conditions to improve efficiency, stability and production. From the raw mill and kiln to the cooler, cement mill and coal mill, it coordinates multiple process parameters, responds to changing operating conditions and helps maintain performance with less reliance on manual intervention.
Raw material variations, fuel quality and changing process conditions are everyday challenges in cement manufacturing. ECS/ProcessExpert helps operators navigate these challenges by continuously optimising process performance.
The objective is simple: deliver better results consistently, not just under ideal conditions, but in the face of everyday operating challenges.
Fuller’s expertise in fuzzy-logic-based process control dates back to the 1980s. Today, that legacy continues through advanced automation and intelligent process optimisation.
ECS/ProcessExpert Self-Adaptive Control goes beyond monitoring and individual loop control. It coordinates multiple control actions to help plants achieve more stable operations, lower energy consumption and improved production.
Produce more. Consume less. Reduce your environmental footprint. And do it by unlocking the potential of your existing assets.
Chinfon Cement: When Results Earn Repeat Business
Fuller Technologies implemented ECS/ProcessExpert across the Raw Mill, Kiln & Cooler, Cement Mill and Coal Mill circuits on Line 2, commissioned in June 2025. Following this implementation, Chinfon Cement awarded Fuller a repeat order for Line 1, covering the same critical production circuits. The second installation was commissioned in October 2026. This was more than another order. It was an opportunity to demonstrate the value of intelligent automation across another production line.
The results demonstrate improvements in both energy efficiency and production across all four process areas on both production lines.
From reduced mill power consumption to increased production and lower kiln heat consumption, the improvements show what intelligent process control can deliver in real plant operations.
Each PXP installation comes with a one-year proactive service agreement. We monitor all KPI parameters for the duration of the agreement. Advanced performance reports are included in the yearly service agreement. Data gathered by PXP is sent to our processing centre at Fuller and used to calculate KPIs related to system utilization and performance. Operating data is reported to help the plant identify the benefits derived from the software and to identify further opportunities for improvement and optimization.
ECS/ProcessExpert acts as an intelligent assistant to the operator, continuously analysing process behaviour and adjusting control actions to help maintain stable, efficient operations. By reducing process variability and reliance on frequent manual adjustments, it helps the plant move closer to optimum performance day after day. Because the real value of automation is not just performing better on the best day. It is performing more consistently every day.
Decarbonisation does not always require new equipment, major capital investment or a plant shutdown. Sometimes, the biggest opportunity lies in making existing equipment work smarter.
For existing plants, ECS/ProcessExpert helps unlock efficiency improvements without major physical modifications. For new plants, it offers an opportunity to build intelligent process optimisation into operations from the beginning.
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