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Ramco is uniquely poised with 35+ years of experience in operating vertically integrated cement plants and a world-class software solution to operate them.

Global Cement Industry faces constant challenges in productivity, energy costs, and environmental impact besides customer satisfaction and competition. Every manufacturer is trying to address them by sustainability and productivity improvement initiatives. Cement producers are adopting Digitalization as the lever. Connected machines and factories unlock value from the abundance of data. It is the only way to future-proof their operations. Transform your operations with Ramco suite of Cement Solutions.

Get crystal-clear insights with Integrated ERP for the cement industry and what's happening around your business.

Optima ProcessSuite

Ramco’s ProcessSuite is an AI/ML enabled Expert Optimizer System enabling strategic execution and optimization of grinding, milling, pyro processing or combined plant operation. It acts as a self-optimizing model that continuously minimizes process variations. When integrated with ERP systems, you can monitor and optimize all the operational processes in real-time.

ProcessSuite delivers

  • Increase throughput
  • Increase yield
  • Reduce variability of key parameters
  • Reduce energy costs
  • Extend assets life
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Optima BlendX

The cement quality has a bearing on cost of recalls and customer satisfaction. Ensuring quality entails optimal raw material blending. It depends on chemical constraints, process limitations, raw material costs and material handling delay.

Ramco Optima BlendX monitors these parameters in real-time and smartly optimizes them to ensure 100% quality across production stages. It is enabled by real-time integration of lab equipment and process control system. It runs on the powerful MPC engine under collaboration with 2-control ApS, a Danish research-oriented company.

BlendX enables
  • Consistent desired product quality
  • Maximize utilization of alternate fuels
  • Enhance energy efficiency
  • Extend mines life
  • Reduce need for stricter homogenization systems
  • Eliminate customer product rejections
  • Reduce Operational Costs
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Plant Data Management (PDM) System

A huge challenge for plant personnel is unavailability of reliable data to analyse operational performance. They painstakingly extract data from disparate data islands and systems to prepare spreadsheets. It hampers their ability to accurately monitor KPIs on time.

Ramco Plant Data Management (PDM) is an information management system with strong analytical capabilities. PDM ensures reliable, accurate and timely availability of information along with customizable dashboards available at the disposal of the entire plant workforce.

PDM delivers
  • Digital backbone for one data-way
  • Link all data islands to the digital backbone
  • Field Integrators for legacy systems
  • One Plant – One Data – One Truth
  • Data Acquisition, Data management
  • Log reporting, interactive dashboards with analytics
  • Accessibility through smart phones, tablets, desktops
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Smart Plant Systems

Ramco Smart Plant is an epitome of Digitalization and Industry 4.0, the most prominent trends in Cement Industry. The concept involves parsing volumes of data from operational systems using AI tools to run the plant on Predictive Outcomes and Business Intelligence. Ramco Smart Plant integrates ERP modules with Advanced Process Control and PDM and interfaces with organizational data lakes, Lab Information Management Systems (LIMS), Energy Management System (EMS), and Manufacturing Execution System (MES).

Smart Plant Systems delivers
  • Realtime Productivity and Efficiency
  • Overall Equipment Effectiveness (OEE)
  • Smart Energy Management
  • Operational and Maintenance Cost Efficiency
  • Product Quality and Traceability
  • HSE (Health, Safety and Environment) and other Regulatory Compliance
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Auditing and Consulting Services

Cement Manufacturing is a complex process with many variants. It includes a broad range of value chain activities such as mining, processing, manufacturing, quality control, inbound and outbound distribution. Globally cement manufacturers face the challenge of ensure process compliance, cost control and emissions control. It requires deep domain expertise to achieve these KPIs.

Our Consulting and Support services include:

  • Operations and Maintenance
  • Auditing
  • De-bottlenecking
  • Performance enhancement Solutions
  • Asset Management
  • Training
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Our Global Customers

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Ramco has been a partner of Eagle Cement Corporation in its Digital Transformation Journey. Our ERP and HCM implementation, integration and digitalization helps our company improve efficiency, processes, and transparency. Our ERP systems are integrated with other systems like LIMS, Truck scales, RTI Automations, GPS. In addition, our Facial Recognition is integrated with HCM HR System. All this has been made possible by Ramco. Enabling portals for Customers and Vendors help us reach out to them in a digital way providing them transparency and ease of transaction with our company. Mobility solution enabled our users to access the system anywhere on any device, thereby increasing productivity. Dashboards and reports provide holistic visualization of our data in systems that improved visibility and analysis to facilitate timely decision-making.

Paulo C. Munoz, Head of IT Systems, Eagle Cement
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Contact Us for Cement Digital Solutions

FAQs

An ERP (Enterprise Resource Planning) system for the cement industry is a software solution that manages and integrates various functions of a cement plant from raw material procurement to product delivery. It provides top-notch end-to-end supply chain management, understands cement manufacturing processes well, and focuses on formula version control, substitution, physical property analysis along with adhering to all the mandatory regulatory compliances. It allows manufacturers to maintain optimum temperature, pressure, and suitable angle in the cement kiln along with predicting the rate of chemical reaction based on the quantities of raw material to form cement clinker on cooling.

It ensures complete visibility into business processes at all levels. Delivery of shipments are closely linked with customer orders. An ERP keeps them both tightly aligned to ensure superior customer experience. 

Cement manufacturing businesses require ERP software to ensure a hassle-free supply chain and monitor the inventory in real-time for a smoother operational flow. It’s also important to manage raw material and fuel requirements for uninterrupted production batches. Moreover, it regulates the addition of intermediates like gypsum to manage the setting time, permeability, resistance to sulfates and aggressive environmental conditions, workability, or higher-quality finishes of cement. Overall, a cement ERP enables data-driven decision-making at levels to ensure efficiency and best customer experience.

Key features of an ideal custom-built ERP software for the cement industry should include:

  • Pre-Configured Mine and Cement Production Process enables ease-of-use
  • Cement Quality Management integrated with Lab Instruments vis-à-vis multiple application/Excel 
  • Entire Dashboard from a single data fabric layer for Effective Cement KPI analytics
  • AI-Modeled Advance Process Control Solution for Cement Plants – Mills and Kilns for Process Control and Blending
  • Formula design based on physical properties analysis, formula security to support intellectual property rights, support for FDA and other compliance requirements, label printing & list of ingredients, HAZMAT bills of lading, VOC, and SARA reporting, BOM and suitable packaging options, bi-directional lot traceability, vendor approval and management, stability or setting time testing, non-conformance and CAPA, complete traceability and costing products, customized COA (Certificate of Analysis) reports, and separate costing of formula and packaging materials.

Cement Industry ERP software gives management visibility over the entire operations and aids the management in strategic decision-making. It helps in integrating all functions of a cement manufacturer from procuring raw materials to production and selling. This ensures tight control over operations, end-to-end, and develops an optimized industry environment.