INSUS reads raw-meal composition, process tags and laboratory history the plant already keeps, and predicts plant-defined quality outcomes before the lab ticket closes. Quality and process teams decide. The lab stays the system of record.
01
Meal chemistry moves continuously.
02
Lab tickets arrive after the window.
03
Advisory only. Predictions stay under plant control.
The problem
Finished cement quality depends on raw-material composition and the process conditions that turn meal into clinker and cement. Limestone, clay, correctives and gypsum properties vary. Blending, kiln and cement-mill conditions move with them. Laboratory results for compressive strength, fineness and setting time remain the system of record, but they arrive after the relevant production window. Teams then correct on a different meal: rework, blending decisions or held product.
The shift
The laboratory stays the system of record. What changes is whether quality and process teams can see the likely outcome while raw-meal or mill conditions can still be challenged.
Today
With INSUS
How it works
This fits OptiStudio as quality decision support above DCS, historian and LIMS. Access is read-only. It does not replace laboratory testing or write setpoints.
Connect
Connect read-only to raw-material and meal composition records, DCS and historian process tags, cement or clinker composition where available, and LIMS quality results such as compressive strength, fineness and setting time.
Understand
Learn how raw-material characteristics and upstream process conditions have related to laboratory quality outcomes on this plant's own history, not from a generic cement template.
Predict
Generate predictions for plant-defined indicators such as compressive strength, fineness and setting behaviour, with uncertainty where the data supports it, before the final laboratory result is available.
Advise
Present predictions, trends and supporting meal or process context to quality managers, process engineers and chemists. People decide whether to investigate meal chemistry, mill settings or hold product. The lab remains the confirmation path.
Verify
Compare each prediction with its eventual laboratory result. Confirmed and rejected outcomes refine the plant-specific model as meal sources and process conditions change.
Getting started
For cement plants where strength, fineness or set are confirmed after the production window has left. Delivered through OptiStudio as quality decision support. Expert Services can help with data assessment and validation. Advisory only. The lab stays the system of record.
Related for cement
Cement quality prediction sits beside clinker temperature optimization and kiln fuel and feed optimization on the same plant.
Meal chemistry and process conditions move while compressive strength, fineness and setting time are still in the lab. This use case predicts plant-defined quality outcomes earlier for quality and process team review.
Raw-material and meal composition, relevant process tags from DCS and the historian, cement or clinker composition where available, and historical LIMS quality results aligned to production periods.
No. Predictions support earlier investigation. Laboratory testing remains the system of record and is used to validate and improve the models.
Day-one delivery is advisory. Predictions go to quality managers, process engineers and chemists. People decide whether to investigate meal chemistry, adjust process conditions or hold product.
Through OptiStudio as quality decision support. Expert Services can support data assessment, integration and validation with your quality and process teams.
No. Cement quality depends on meal chemistry, process condition and operating practice. Value is judged against agreed baselines on the pilot product or line.
Models are plant- and product-specific and do not transfer unchanged. Missing composition or quality history is a data prerequisite. Predictions do not replace statutory tickets or quality reporting.
Cement · Quality · Raw meal
A back-test on one product line and the quality tickets you already keep will show how early meal chemistry and process tags already signal strength, fineness or set risk.
