Vibration Monitoring Solutions for the Cement Industry
For use in kiln drives, crushers, screens, conveyor belts, raw mills, elevators, separators and blowers
Optimising Cement Manufacturing with Precision Vibration Monitoring
The cement industry operates in some of the harshest industrial environments, where extreme temperatures, high levels of airborne particles, and heavy mechanical loads place significant strain on machinery. Ensuring the reliability of equipment in such conditions is crucial to maximising uptime, improving efficiency, and reducing maintenance costs.
At Hansford Sensors, we provide industry-leading vibration monitoring solutions tailored to the unique challenges of the cement manufacturing process. Our high-performance accelerometers and vibration sensors are specifically designed to detect early warning signs of mechanical failure, allowing cement plants to implement predictive maintenance strategies that minimise costly downtime.
The Importance of Vibration Monitoring in Cement Manufacturing
Cement production involves a series of complex mechanical processes, including raw material crushing, grinding, kiln operation, and finished product handling. Each stage presents risks of mechanical wear, misalignment, and imbalance that can lead to severe machinery failure if left unchecked.
Key areas of concern include:
- Kiln Drives & Rotary Kilns – The heart of any cement plant, rotary kilns operate under extreme conditions. Misalignment and improper loading can cause excessive wear on bearings, leading to failures that halt production.
- Crushers & Screens – Constant impact and vibration from processing raw materials create a high-risk environment for rotating components. Bearing degradation and imbalance can lead to reduced efficiency and unplanned stoppages.
- Mills (Raw, Finish, and Ball Mills) – Grinding operations are among the most energy-intensive processes in cement manufacturing. Unchecked vibration can indicate bearing damage, excessive gear wear, or drive misalignment.
- Conveyor Belts & Elevators – Critical for material transport, these systems are prone to misalignment and mechanical wear, often resulting in unexpected breakdowns.
- Fans, Blowers & Separators – Essential for maintaining airflows and dust control, high-speed fans and separators require continuous monitoring to detect imbalance, cavitation, and bearing wear.
By implementing continuous vibration monitoring, cement plants can prevent these issues before they escalate, ensuring maximum efficiency and extended equipment lifespan.
Hansford Sensors: Precision Monitoring for Cement Plants
Hansford Sensors offers a comprehensive range of industrial vibration sensors engineered for the demanding conditions of cement manufacturing. Our solutions provide:
Early Fault Detection – Identify bearing wear, misalignment, and imbalance before failure occurs.
Reduced Downtime – Predictive maintenance enables timely repairs, minimising costly production halts.
Improved Equipment Efficiency – Ensure optimal performance of motors, gearboxes, and conveyors.
Enhanced Safety & Compliance – Monitor critical assets to maintain safe operating conditions.
Vibration Sensor Solutions for Cement Plants
We provide a selection of sensors specifically suited to cement manufacturing applications, including:
- HS-100 Series Industrial Accelerometers – Rugged, stainless-steel sensors designed for extreme environments, available in top- and side-entry models.
- HS-420 4-20mA Sensors – Ideal for integration into PLC systems, allowing real-time monitoring and automated alerts.
- HS-535 Triple Output Accelerometers – Advanced multi-output sensors capable of measuring bearing condition, imbalance, and misalignment.
- HS-510 Local Monitoring Modules – Providing relay-based alarms for on-site equipment protection.
- HS-570 & HS-580 Enclosures – Industrial-grade enclosures for protecting sensors in dusty, high-temperature environments.
These solutions allow cement manufacturers to implement both offline and online monitoring, depending on plant needs.
How Vibration Monitoring Improves Cement Plant Performance
Predictive Maintenance: By continuously measuring vibration levels, our sensors provide real-time insights into machinery health, allowing maintenance teams to intervene before breakdowns occur.
Increased Operational Efficiency: With reliable equipment performance, cement plants can operate at optimal production capacity, reducing energy costs and improving overall yield.
Cost Savings: Early fault detection prevents catastrophic failures and reduces unplanned maintenance costs, translating to significant financial savings.
Extended Equipment Lifespan: Proper monitoring ensures longer-lasting motors, gearboxes, and bearings, reducing the need for premature replacements.
Enhanced Safety & Compliance: Minimising mechanical failures reduces safety risks for operators and helps plants meet stringent regulatory standards.
Trusted by Leading Cement Manufacturers
Hansford Sensors has been a trusted partner for cement producers worldwide, delivering high-performance vibration monitoring solutions that enhance efficiency, reliability, and safety. With our proven expertise in harsh industrial environments, we help cement plants optimise production and reduce maintenance overheads.
Get in touch with our experts today to discuss your specific requirements and discover how Hansford Sensors can enhance your plant’s performance.
Typical solutions for the Metals Industry
Real Time Monitoring
Our tough and reliable AC sensors (HS-100 Series) can be used with local switch or connection boxes (HS-SE), to allow data to be collected via handheld devices.
High Sensitivity & Intrinsically Safe
For low speed applications, with slowly rotating machinery, we offer the option of our specially modified low frequency response accelerometer (HS-100F Series), or a higher sensitivity option of our AC range of sensors.
Monitoring Imbalance
Our 4-20mA accelerometers (HS-420 Series) are designed to be permanently connected to PLCs (programmable logic controllers) for continuous data logging and real time trend analysis.
Restricted Access
Our side exit (HS-100S Series) and compact (HS-180S) AC accelerometers, are great for use in areas where there is limited access.
Extra Options
We offer advanced systems for monitoring vibration and bearing conditions. These combine AC sensors connected via a vibration module (HS-500 Series) for optimum machine protection. Data readings can be displayed and alarmed both locally and connected back to a PLC for higher level system integration.
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Global Customer Service & Support
We have a global network of sales partners, backed by the resources of our central product design, manufacturing and customer centre in the UK. Our sales partners include vibration analysts, consultants and system builders and integrators. Each is fully trained, experienced in meeting the challenges of vibration monitoring in a wide range of industrial applications and capable of providing dedicated local technical, engineering and customer service, wherever you are in the world.
For fast, friendly advice, and to learn more about our products, please contact our sales team.