Case Studies
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Optimized grinding through real-time state-of-the-art particle analysis at Cyment
Cyment, a European pioneer in sustainable binder technology, focuses on reducing the environmental footprint of concrete while maintaining strict technical performance specifications. The company operates across multiple European markets with applications in construction projects. Achieving this goal requires a highly consistent particle size distribution (PSD) during dry grinding operations.
However, traditional laboratory-based particle size analysis provided only delayed and intermittent data, thereby limiting the ability to respond to process fluctuations in real-time. Variations in PSD affected product consistency, energy efficiency, and overall process stability—critical factors for quality assurance and sustainability targets.
To address these challenges, Cyment partnered with CEMTEC to implement the CEOPS - CEMTEC Online Particle Size Analyzer, a fully integrated, real-time monitoring system for dry grinding circuits at its Hungary-based production facility.
Implementation & Commissioning
The CEOPS system was installed at the end of 2024 and successfully commissioned in the first quarter of 2025. The optimal sampling position was identified in the area between an air slide and the finished product bucket elevator. In addition to process-relevant parameters such as material flow and negative pressure in the equipment lines, space conditions with proper accessibility were also carefully evaluated.
Following installation, a defined testing and validation phase was carried out, during which online PSD data were correlated with laboratory laser analysis results. Communication and data exchange are facilitated through Profinet, an industry-standard protocol built on Industrial Ethernet. The system is in continuous operation and is regularly used by both the production and quality departments, providing significant added value. Operating alongside the grinding line, it delivers reliable, high-quality data that helps the customer optimize production and ensure both process and product stability.
An extension of the project with a second sampling unit is already under discussion and is expected to be realized in Q1/2026.
Challenge
- Maintaining consistent product fineness in dry grinding operations
- Variations in particle size distribution impacting downstream processes, product performance, and overall plant efficiency
- High energy consumption while improving grinding performance
- Lack of real-time process control
- Traditional lab measurements are time-consuming and provide intermittent snapshots
- Meeting sustainability goals alongside productivity
Solution
- The CEOPS project, consisting of screw sampler & one measuring unit was launched at end of 2024 & successfully commissioned in Q1/2025
- Following installation and a defined testing period, CEOPS measurement results were aligned and correlated with those from lab laser analysis
- Profinet, a standard protocol built on Industrial Ethernet, facilitates communication & data exchange
- Continuous, high-resolution PSD measurements using laser diffraction technology
Result
- Continuous, real-time measurement of particle size distribution
- Combining optimized raw material formulation, the facility achieves a specific CO2 footprint of 26.2 kg/t for its products
- Highly accurate laser diffraction analysis
- Representative & consistent sampling
- Fast detection of process fluctuations
- Improved product fineness
- Reduction of overgrinding and associated energy costs
- Seamless integration with existing plant control infrastructure
- Customizable setup for different materials and flows
Return on Investment & Sustainability
CEOPS delivers a fast and measurable return on investment, with payback typically achieved within 6 to 12 months, depending on the process and material. This is driven by lower energy consumption, more consistent product quality, reduced wear on grinding equipment, and greater overall process stability.
From a sustainability standpoint, CEOPS enables a more efficient use of both raw materials and energy. By preventing overgrinding and stabilizing particle size distribution, the system helps reduce CO₂ emissions and aligns with industry goals for environmentally responsible production.
Conclusion
This reference project demonstrates how digitalization and sustainability can be successfully combined. By implementing CEOPS, Cyment transformed particle size measurement from a periodic laboratory task into a powerful real-time control tool—enabling stable production, improved energy efficiency, and consistent high-quality output.
With CEOPS, CEMTEC once again proves its ability to deliver innovative, practical, and future- oriented solutions for modern grinding operations.
CEOPS at Cyment Plant
