AI in Cement Manufacturing: Redefining Energy Efficiency & Cost Allocation

1. Redefining Energy Efficiency in the Cement Industry with AI-Powered Energy Management Energy management directly impacts profitability, compliance, and environmental performance. Yet, many manufacturers still struggle to track consumption accurately, allocate costs efficiently, and make real-time energy decisions across multiple production lines. A leading cement manufacturer in the Middle East faced this exact challenge. With multiple mills, shared energy meters, and over ten different cement products, the company struggled to assign energy costs accurately across product categories. The lack of visibility into product-specific energy data limited its ability to plan finances, optimize resources, and set accurate pricing strategies. Recognizing the need for a smarter approach, the manufacturer partnered with Greenovative Energy to deploy its advanced AI-driven GreenErgy Platform, a complete energy and sustainability management solution designed to transform the way industries manage, monitor, and optimize their resources. The Challenge: Incomplete Visibility and Complex Cost Allocation Cement plants are among the most energy-intensive industrial facilities, consuming significant power across milling, blending, and kiln operations. Without product-level energy visibility, cost allocation becomes ambiguous, making it difficult to identify inefficiencies or plan budgets. The absence of precise energy data also complicates sustainability reporting, often leading to inaccurate carbon footprint assessments. In this case, the manufacturer’s shared energy meters across three mills made it impossible to determine how much power each cement product consumed. This created bottlenecks in financial analysis, pricing accuracy, and operational efficiency. The Solution: AI-Driven Energy Intelligence

2. Greenovative implemented the GreenErgy Platform, an AI-based Energy Management System (EMS) that transforms raw plant data into actionable insights. The system uses advanced analytics, automated metering, and machine learning algorithms to deliver product-wise energy breakdowns, detect inefficiencies, and forecast demand. By integrating with existing infrastructure, GreenErgy provided the manufacturer with: Granular visibility into product-level energy use across multiple mills. • Automated cost allocation based on real-time consumption data. • AI-backed insights that enabled plant managers to make data-driven energy decisions. • Centralized dashboards for compliance, carbon tracking, and sustainability reporting. • This transformation not only improved accuracy in cost allocation but also helped the company align energy usage with production goals, reducing waste and enhancing overall energy efficiency. The Impact: From Data to Decarbonization The introduction of GreenErgy redefined how energy was viewed, measured, and managed across the plant. By enabling precise tracking and intelligent forecasting, the system empowered leadership teams to take proactive decisions that improved cost efficiency and reduced carbon intensity. Within months, the cement manufacturer achieved: Improved cost visibility across all product categories. • More accurate energy budgeting and forecasting. • Enhanced sustainability metrics for ESG and carbon compliance. • This collaboration set new benchmarks in energy management for the cement sector, demonstrating how AI- powered solutions can create tangible value, operationally, financially, and environmentally. If your manufacturing operations face similar challenges in tracking, allocating, or optimizing energy, explore how Greenovative’s GreenErgy Platform can help your organization achieve measurable results. ? ? Continue reading the full case study here