Minimizing downtime in the cement manufacturing industry is crucial, as each minute of operational delay can lead to significant financial repercussions. With the dual challenges of maintaining aging machinery and adapting to variable environmental conditions, cement producers increasingly turn to predictive maintenance and condition monitoring to ensure continuous and efficient operations.
This case study explores the collaboration between cement manufacturer Buzzi Unicem USA and Waites Sensor Technologies. By leveraging cutting-edge sensor technology, expansive machine learning, skilled human analysts, and proactive maintenance strategies, this partnership significantly improved equipment reliability and operational efficiency, saving over $1 million in unplanned downtime thus far, according to cost savings calculated and reported by Buzzi Unicem USA.
About Buzzi Unicem USA
Based in Bethlehem, Pennsylvania, Buzzi Unicem USA is one of the largest cement manufacturers in the country. Its seven large cement plants have the capacity to produce nine million metric tons of cement, and its products are distributed to over 30 states.
Dennis Denoski, corporate maintenance engineer, focuses on enhancing equipment reliability and minimizing downtime. "Our objective is to move from reactive to preventive maintenance, and Waites' technology has been crucial in this transformation," he says.
Meeting Maintenance Challenges
Prior to the collaboration, Buzzi Unicem USA relied on monthly, third-party vibration analyses, meaning maintenance was reactive, not predictive. Delayed maintenance leads to frequent equipment failures, unplanned downtime, and operational disruptions.
Denoski explains, “Monthly vibration analyses often left us without critical data for extended periods. Technicians, unfamiliar with our sites, missed important readings, exacerbating the gaps in our maintenance efforts. This reactive approach was not sustainable, leading to significant unplanned downtime and increased maintenance costs.”
Implementing Waites' System
Denoski knew that something had to change. "We started conversations with Waites in the third quarter of 2022," he explains. "We tested its system at our Stockertown facility and then at our Alamo facility in early 2023. The cost-effectiveness and performance of its wireless solution were key factors in our decision." Once their minds were made up, Buzzi Unicem USA fell in love with the system's easy installation and the attentive support of the Waites team.
Waites collaborated closely with Buzzi Unicem USA to develop a predictive maintenance system that addressed both technological and human factors. Within two months of initial contact, Waites surveyed the site, carefully selected the right sensors for each specific application, and planned out the wireless mesh network to allow continuous sensor communication. The result was a fully operational condition-based monitoring system. From installation to in-depth staff training, Waites ensured that Buzzi Unicem USA's transition to a predictive maintenance model was fast and seamless.
The System in Action: Successful Predictive Maintenance Results
Figure 1: Buildup on a fan at a Buzzi Unicem USA cement facility
Problem Identified: A rapid increase in vibration was detected on the fan shaft at Buzzi Unicem USA’s Alamo Cement Company San Antonio facility. The high vibration levels indicated a potential imbalance due to buildup on the fan, necessitating immediate inspection and corrective action to prevent severe damage to the fan and associated components.
Figure 2: Fan shaft readings showing high vibration levels
Quick Resolution: The sensors installed by Waites detected the vibration anomaly, so the analysts prompted the maintenance team to inspect the fan, discovering that a buildup on the fan was causing the imbalance. The team performed grit blasting while the fan was running to remove the buildup. This maintenance action effectively reduced the vibration levels to an acceptable range, as shown in Figure 3. The fan bearings were also checked for wear and lubrication levels were inspected to ensure proper functioning. Continuous monitoring was established to detect any further anomalies.
Figure 3: Fan shaft sensor readings after grit blasting
Significant Savings: This predictive maintenance action avoided eight hours of unplanned downtime. It resulted in cost savings in the tens of thousands, highlighting the effectiveness of Waites' predictive maintenance technology in identifying and resolving potential equipment issues before they escalate.
Real-Time Monitoring Cuts Downtime
Currently, Waites provides Buzzi Unicem USA with vibration analysis for critical equipment, such as mills, kilns, clinker coolers, fans, conveyors, crushers, compressors and pumps, covering all plant areas from raw material handling to finish grinding.
Waites uses detailed, component-level analysis to predict and prevent failures. The shift from monthly reports to real-time monitoring has been transformative. "Now, instead of getting a report once a month, we receive action items on the dashboard as soon as an issue is detected," says Denoski. This immediate notification enables the maintenance team to quickly inspect and address issues, significantly cutting response times and preventing downtime.
Measurable Impact and Savings
Waites' condition monitoring and predictive maintenance services have significantly improved Buzzi Unicem USA's operations. Early detection and recommendations helped avoid more than 600 hours of unplanned downtime, saving around $1 million in production losses and emergency repair costs, according to the cement manufacturer. This includes savings from preventing major equipment failures, reducing emergency maintenance, and optimizing repair schedules. By identifying issues, like bearing defects, lubrication problems, and early misalignments, Waites extended the life of critical equipment and improved overall reliability.
This predictive maintenance approach allowed the company to schedule repairs during planned downtimes, minimizing production disruptions and enhancing safety by reducing the risk of catastrophic failure. Waites' detailed analysis helped address recurring issues, improving long-term performance. The partnership has optimized Buzzi Unicem USA's maintenance strategies, reduced costs, and enhanced operational efficiency, contributing to a stronger bottom line for its cement manufacturing operations.
Future Expansion Plans
The cement manufacturer plans to expand its use of Waites' vibration monitoring systems and services, deploying over 500 sensors across all plants to boost predictive maintenance and equipment reliability. The company is also exploring integrating the Waites dashboard with existing programmable logic controller (PLC) systems to streamline data flow and enhance real-time monitoring.
The collaboration between Buzzi Unicem USA and Waites Sensor Technologies demonstrates the potential of advanced condition monitoring systems in the cement industry. Buzzi Unicem USA has significantly improved operational efficiency, reduced unplanned downtime, and achieved substantial cost savings by shifting from reactive to proactive maintenance. Waites' continuous monitoring technology has greatly improved response times to equipment issues and enabled better predictive maintenance strategies, extending the life of critical machinery and optimizing repair schedules.
