ECS/ProcessExpert^® advanced process control software

Cement plants face constant variability in raw materials, alternative fuels, and operating conditions that challenge traditional control systems. Our self-adaptive controller eliminates the need for complex mathematical models, evaluating process information in real time and adapting continuously without operator intervention. The result is fewer process upsets, higher utilization rates, and consistent performance over the long term — more resilient to process changes than conventional model predictive control and capable of superior dynamic predictions.

AI-based soft sensors, developed in partnership with Imubit, close the gap between data and control by addressing one of the cement industry's biggest challenges: the blind spots in real-time process and quality data caused by delayed laboratory results and harsh operating conditions that limit physical sensor placement. Predictions are fed directly into PXP, enabling enhanced real-time optimization across three critical parameters: free lime, Blaine fineness, and kiln inlet O₂. Soft sensors are available for integration in newer PXP installations.

Our cloud-based PXP Insights 2.0 module provides enterprise-level benchmarking across your entire operation, with real-time KPI monitoring across multiple sites transforming complex multi-plant data into clear, actionable intelligence. Configuration changes sync automatically, external baseline data can be imported directly for transparent performance-guarantee comparisons, and dedicated sustainability dashboards provide global visibility of CO₂ savings with regional conversion factors configurable by country.

PXP DataBooks provides a collaborative framework for process specialists and data scientists to develop new AI solutions together and deploy them seamlessly into any control strategy in real time. The platform supports inference of machine learning and deep learning models trained offline, bringing advanced prediction, anomaly detection, and condition monitoring capabilities directly to your plant floor.

Controller performance degrades over time — often gradually enough to go unnoticed until it is costing you. Our control loop performance monitoring (CLPM) tool identifies underperforming control loops and diagnoses problems before they affect plant efficiency, using statistical metrics to ensure parameters remain stable precisely at the target. Visual time series and column charts provide immediate insights across flexible timeframes, enabling corrective action before efficiency losses occur.

Every PXP installation includes a one-year service agreement featuring bi-monthly remote service visits and annual onsite support. Our experts continuously monitor KPI parameters and deliver advanced performance reports, identifying both realized benefits and untapped optimization opportunities. The PlantLine™Essential service framework provides the foundation for expanded support through optional modules, including lifecycle management, cybersecurity, and remote technologies.