Intelligent Solutions for
Intelligent Solutions for
Intelligent Solutions for
Cement Industry
Cement Industry
Cement Industry
End-to-end automation and AI monitoring from raw material handling to packing improving uptime, energy efficiency, and environmental compliance.
25%
Energy efficiency improvement
Real-time monitoring
Kiln, crusher, and conveyor systems
ISO 50001
Energy management certification ready
Trusted by Leading Enterprises Globally
Trusted by Leading Enterprises Globally
Industry Hazards
Most Common Challenges in
Cement Industry
Each one has a measurable impact in downtime, safety, energy costs, or compliance readiness. Without continuous monitoring, they persist across shifts.
Unplanned Kiln Shutdowns
Unplanned Kiln Shutdowns
Unplanned Kiln Shutdowns
Crusher & Mill Breakdowns
Crusher & Mill Breakdowns
Crusher & Mill Breakdowns
Conveyor Belt Damage
Conveyor Belt Damage
Conveyor Belt Damage
Safety Gear Non-Compliance
Safety Gear Non-Compliance
Safety Gear Non-Compliance
Dust & Fire Hazards
Dust & Fire Hazards
Dust & Fire Hazards
Limited Plant Visibility
Limited Plant Visibility
Limited Plant Visibility
Energy Overconsumption
Energy Overconsumption
Energy Overconsumption
Environmental Compliance Gaps
Environmental Compliance Gaps
Environmental Compliance Gaps
Our Solutions
Scalable Capabilities for
Every Challenge
Connects to your existing kiln DCS, conveyor PLCs, and SCADA systems over Modbus, Profinet, and EtherNet/IP. Deployed on your current plant network.
Safety Monitoring
AI-powered monitoring that detects safety violations, PPE non-compliance, and hazards across kiln areas, crusher zones, and conveyor lines.
Security & Access Control
Automated perimeter surveillance, vehicle management, and identity verification across plant entry points and restricted zones.
Operations Intelligence
Real-time tracking of vehicle movement, material flow, worker activity, and energy consumption across the cement production chain.
01
Safety
Safety Helmet & Vest Detection
Monitors whether workers in kiln areas, crusher zones, and loading bays are wearing required helmets and high-visibility vests. Instant alerts with camera location, timestamp, and visual evidence.
02
Safety
Safety Harness Detection
Detects workers at elevated platforms, inspection walkways, and structures who are not properly harnessed. Alerts are triggered before an incident occurs, not after.
03
Safety
Fire & Smoke Detection
Identifies fire and smoke at the earliest visible stage across raw material storage, kiln surroundings, and packing areas — effective in high-dust environments where traditional detectors fail.
04
Safety
Person Under Suspended Load
Detects personnel standing beneath crane loads or suspended equipment in material handling areas. Real-time alerts give operators the seconds needed to stop the lift and clear the zone.
05
Safety
Crowd & Occupancy Monitoring
Tracks the number of workers in confined zones, kiln maintenance areas, and high-risk sections. Alerts when occupancy exceeds safe limits for the area.
06
Safety
Object Detection in Pathways
Identifies materials, equipment, or debris left in walkways and vehicle access routes — preventing collision and tripping hazards in high-traffic plant areas.
07
Safety
Safety Shoes Detection
Monitors footwear compliance in zones where heavy material handling, heat, and falling objects present daily risks. Violations flagged without manual supervision.
08
Safety
Vehicle Safety Monitoring
Checks vehicles on internal roads for headlights, wheel stoppers, and correct parking zones — particularly relevant at clinker loading bays and raw material yards.
Safety Monitoring
AI-powered monitoring that detects safety violations, PPE non-compliance, and hazards across kiln areas, crusher zones, and conveyor lines.
Security & Access Control
Automated perimeter surveillance, vehicle management, and identity verification across plant entry points and restricted zones.
Operations Intelligence
Real-time tracking of vehicle movement, material flow, worker activity, and energy consumption across the cement production chain.
01
Safety
Safety Helmet & Vest Detection
Monitors whether workers in kiln areas, crusher zones, and loading bays are wearing required helmets and high-visibility vests. Instant alerts with camera location, timestamp, and visual evidence.
02
Safety
Safety Harness Detection
Detects workers at elevated platforms, inspection walkways, and structures who are not properly harnessed. Alerts are triggered before an incident occurs, not after.
03
Safety
Fire & Smoke Detection
Identifies fire and smoke at the earliest visible stage across raw material storage, kiln surroundings, and packing areas — effective in high-dust environments where traditional detectors fail.
04
Safety
Person Under Suspended Load
Detects personnel standing beneath crane loads or suspended equipment in material handling areas. Real-time alerts give operators the seconds needed to stop the lift and clear the zone.
05
Safety
Crowd & Occupancy Monitoring
Tracks the number of workers in confined zones, kiln maintenance areas, and high-risk sections. Alerts when occupancy exceeds safe limits for the area.
06
Safety
Object Detection in Pathways
Identifies materials, equipment, or debris left in walkways and vehicle access routes — preventing collision and tripping hazards in high-traffic plant areas.
07
Safety
Safety Shoes Detection
Monitors footwear compliance in zones where heavy material handling, heat, and falling objects present daily risks. Violations flagged without manual supervision.
08
Safety
Vehicle Safety Monitoring
Checks vehicles on internal roads for headlights, wheel stoppers, and correct parking zones — particularly relevant at clinker loading bays and raw material yards.
Safety Monitoring
AI-powered monitoring that detects safety violations, PPE non-compliance, and hazards across kiln areas, crusher zones, and conveyor lines.
Security & Access Control
Automated perimeter surveillance, vehicle management, and identity verification across plant entry points and restricted zones.
Operations Intelligence
Real-time tracking of vehicle movement, material flow, worker activity, and energy consumption across the cement production chain.
01
Operations
Vehicle Turnaround Time Tracking
Tracks every truck from entry to exit — linked to number plate. Identifies delays at weigh bridges, loading bays, and dispatch points to improve fleet efficiency.
02
Operations
Worker Productivity Analysis
Monitors workstation occupancy and activity levels across production shifts. Identifies idle time and helps operations teams optimise workforce allocation without manual reporting.
03
Operations
Tarpaulin Detection
Checks that outgoing trucks carrying clinker, cement, or raw materials have tarpaulin covers fitted before they leave the gate — reducing road spillage and meeting transport compliance requirements.
04
Operations
Clinker Detection on Conveyors
Identifies clinker presence, foreign objects, and material irregularities on moving conveyor belts using computer vision — preventing belt damage and unplanned stoppages in the clinker feed line.
05
Operations
Bag & Product Counting
Automatically counts cement bags on packaging lines and loading bays — replacing manual tallying with accurate, real-time dispatch records.
06
Operations
Energy Monitoring Dashboard
Per-section energy tracking across grinding, heating, and material handling processes. Flags overconsumption against benchmarks and provides the structured data required for ISO 50001 reporting.
Our Capabilities
Our Capabilities
Complete Operational Technology Stack for
Cement Industry
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Standards
Built to Meet the Standards
Your Industry Requires
Every system KGT deploys for steel and metal operations is designed to meet or exceed the compliance standards that govern your industry.
If your plant has gaps in any of the areas listed below, whether in safety documentation, environmental monitoring, traceability, or cybersecurity - our team will assess what is missing and build the infrastructure needed to support certification.
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Industrial Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
Vizibelt is an Ai-powered monitoring system designed for conveyor operations - detecting foreign objects in real time and preventing belt failures before they disrupt production.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
0+
0+
Reduction in Downtime
0%
0%
Increase in Productivity
0%
0%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC