ECS/ProcessExpert^® advanced process control software

Based on documented customer installations, you can expect 7-8% total improvement versus manual operation. CEMEX Croatia achieved exactly these numbers: 7-8% higher mill feed rate and lower specific power consumption. GCC Chihuahua saw 4.2% production increase with 31% reduction in free lime variation. Specific benefits include up to 7% fuel reduction, up to 2% CO2 footprint reduction, and minimum 10% increase in alternative fuel usage. The self-adaptive technology in v9.1 delivers an additional 2-3% improvement over previous versions. ROI typically occurs within one year depending on application, with indirect benefits including extended equipment life and reduced maintenance costs.

Traditional process control uses fixed parameters that require multiple controllers for different operating conditions. Our self-adaptive technology dynamically adjusts tuning parameters in real-time using current data, not historical models. This patented technology from Lin & Associates handles all process scenarios within a single controller. There's no need for regular retuning or retraining. The system learns continuously and adapts to changing conditions like different alternative fuels or raw material variations. The result? This controller delivers superior stability and responsiveness compared to traditional advanced process control systems, with significantly higher utilization rates even during initial commissioning phases.

Our structured eight-step implementation model provides professional support to ensure reliable performance. You'll work with a dedicated project manager who acts as your main contact throughout the entire project lifecycle. The process includes comprehensive planning, client interviews, application design, primary system commissioning with onsite monitoring, operator training, remote fine-tuning, handover, and long-term support establishment. Each phase is designed to minimize disruption while ensuring successful deployment. Our customers consistently praise the implementation experience. Chinfon Cement specifically highlighted our outstanding communication skills, excellent project execution, and noted how quickly their operations team became comfortable with our approach. This reflects our commitment to adapting the structured process to each plant's unique complexity and requirements.

ROI typically occurs within one year depending on application. Our subscription model often reduces initial investment by 50% or more compared to perpetual licensing while providing continuous value through automatic updates and service coverage. You pay implementation costs upfront, then a fixed annual fee after final acceptance. This converts large capital expenditure into predictable operational expense – no more budget approvals for software upgrades. Typical agreements run three years and include PlantLine service coverage with proactive monitoring and support. You'll always have the latest features like our emission control enhancements, whereas perpetual license holders often run outdated versions. It's innovation as a service, ensuring maximum long-term value from your investment.

Yes. We support all major PLC brands including Rockwell Automation, Siemens, and Schneider through specific I/O drivers. We also provide industry-standard OPC UA integration for most existing control systems. We've successfully installed on ThyssenKrupp lines with ABB control systems, demonstrating our cross-platform flexibility. The software runs on standard PCs with user-friendly graphical interfaces and includes built-in PLC communication drivers for real-time testing. Our integration approach validates all measurements before use and includes comprehensive troubleshooting capabilities. You won't need to replace your existing control infrastructure – we enhance what you already have while preparing you for future Industry 4.0 capabilities.

Your existing process engineers or chemical engineers can easily operate the system after our comprehensive training. No specialized programming or automation expertise required. Our 50+ years of cement domain knowledge is embedded directly into smart objects and intuitive interfaces. The decision tree component shows process status and underlying reasoning, making it easy for operators to understand system actions. Many customers run PXP applications independently after training. When the system isn't in automatic mode, advisory mode recommends specific actions to operators. Industry leaders like Chinfon Cement specifically point out how quickly their operations team became comfortable with the system execution style. The technology adapts to your team, not the other way around!

We provide complete coverage: pyroprocess (kiln, cooler, calciner), vertical roller mills, and ball mill circuits. Each application requires its own dedicated instance, but multiple applications integrate seamlessly. Our fuel distribution module optimizes alternative fuel usage based on cost and heat value. Recipe control handles changeovers in both raw and finish mills. Mill ramp-up functionality ensures smooth startups with minimal equipment wear. The system delivers holistic solutions customized to each plant's specific configuration. Whether you need upset condition management, emissions control, or production optimisation, our modular approach scales with your requirements. There's no limit to the number of kilns that can be controlled – each gets its own optimized application.

Every installation includes a one-year proactive service agreement with remote visits every two months plus annual onsite support. Our service coverage includes performance monitoring and advanced KPI reporting. Optional PlantLine service packages expand capabilities: Proactive maintenance services, Lifecycle module for latest software features, Cybersecurity with managed protection, and Remote Technologies enabling Go2FLS mobile access for troubleshooting from anywhere. Our global service network monitors your system performance and identifies optimisation opportunities. We don't just install and disappear – we're invested in your long-term success. The subscription model includes continuous service coverage, ensuring peak performance throughout the system lifecycle.

ECS/ProcessExpert delivers up to 2% overall CO2 footprint reduction through optimized operations. Real installations show 16-17% increases in alternative fuel usage while maintaining process stability. Our PXP Insights module provides sustainability-focused dashboards with global visibility of CO2 savings achieved by the software. Better clinker quality consistency enables reduced clinker factors in final cement. Energy efficiency improvements include up to 5% heat consumption reduction and up to 7% power reduction. The fuel distribution module ensures optimal alternative fuel mixing based on cost and heat value, supporting your transition to waste-derived fuels. Integrated emissions control manages NOx reduction automatically. These aren't theoretical benefits – customers like GCC Chihuahua demonstrate significant alternative fuel increases while improving overall process performance.

We offer the only known advanced process control solution built specifically for cement by cement industry experts. Our 50+ years of domain knowledge and thousands of worldwide installations provide unmatched process understanding. The self-adaptive technology represents a generational advance in cement process control versus traditional static systems. Our subscription model ensures continuous innovation access, while comprehensive service agreements guarantee long-term success. Unlike generic automation suppliers, we integrate seamlessly with our broader automation ecosystem including ECS ControlCenter and QCX systems. We're Industry 4.0 ready with cloud capabilities, enterprise benchmarking, and mobile access. When you choose FLSmidth Cement, you're partnering with the process knowledge experts who understand cement production better than anyone else.