Virginia based heavy building materials producer Titan American has implemented machine learning in production technologies at its two cement plants in the eastern United States, resulting in enhanced equipment throughput and reliability, reduced energy consumption, and improved product consistency and quality.

Titan America has deployed autonomous AI real-time optimisation algorithms that dynamically process data from plant sensors and continuously adjust variables, bringing the equipment to optimum operational performance. With each iteration, the AI algorithms maximise throughput and decrease energy consumption in all the main assets of the plants.

The company has implemented plant-wide failure prediction systems that continuously receive and analyse signals from thousands of sensors to detect process and equipment operation abnormalities significantly earlier than could be otherwise detectable. The alerts generated are reviewed and evaluated by dedicated teams in remote service centres.

AI-based predictive quality applications, supported by sophisticated quality control equipment, are being implemented to predict cement performance at the time of production, enabling plant operators to improve the grinding process, lower clinker consumption, and ensure consistent product quality and performance resulting in less carbon footprint.

Building on its experience in digitalising its manufacturing process, Titan America is now planning on the deployment of similar digital and predictive application solutions to optimise its logistics and distribution systems.

Bill Zarkalis, President & CEO: “A systematic process of test and learn that started several years ago has reached an important milestone. Titan America is today at the forefront within our Industry. But we know this race is a marathon, a continuous process of reimagining and redesigning the way we produce and offer our products and solutions to meet the fast-changing market and community needs. As we continue to build digital capabilities within our manufacturing, logistics and customer-care processes, we remain focused on our mission to offer innovative construction materials and solutions that improve life on our planet.”