Production Optimization

Autonomous Kiln & Mill Control Closing the loop between the lab and the shop floor

Unified IT-OT Ecosystem

Integrating data across  Raw Mills, Kilns, and Grinding units for plant-wide KPI analytics across production and quality.

Smart LIMS & Quality Integration

Digitize quality data of XRF spectrometers, Particle Size Analyzers and other quality testing equipments. Perform SPC, Golden Batch chemistry analytics. Integrate with MES and ERP for realtime actions.

Cement Strength Prediction

Predicting the 1 day, 3 day, 7 day and 27 day cement strength based on clinker quality, additives and grinding process parameters.

C3S Prediction

Real time Prediction of C3S in clinker produced from Kiln for real time fine fine tuning of KILN process parameters and AFR utilization.

Energy & Utilities

Precision Thermal & Power Analytics Maximizing WHRS recovery and minimizing NHR

Solar Efficiency and Loss Tracking

Tracking the captive solar plant KPIs like generation, CUF, PR ratio. Also providing analytics on losses caused due to unbalanced string currents, invertor conversion,  soiling etc.

Energy Management

Classic but effective tools to map and monitor the plant wide energy meters. Providing alerts on power quality, high demand, over equipment consumption, high motor current, low PF etc.

AI based for Power Plant NHR Reduction

AI-driven optimization for captive thermal Power Plants specifically designed to reduce Net Heat Rate (NHR). Providing automated problem identification, root cause and recommendations to improve KPIs across boilers, turbine, condensors & auxilary power equipments.

AI Diagnostic Agent for SEC

Monitors the mill and kiln areas for high energy consumption and coorelates with TPH, sub equipment energy consumption, process parameters and idle energy.

Demand Forecasting and Power Mix Optimization

Predicting the energy demand based on production and maintenance schedule, Renewable energy generation, waste heat generation to effectively plan power allocation for captive thermal, DISCOM and IEX.

Kiln SHC and TSR Optimization

Providing control recommendation to optimize the specific heat consumption of cement kiln while balancing the kiln economy with AFR utilization and clinker quality.

Intelligent Maintenance

Predictive Asset Reliability Eliminating the "Silent Killers" of cement production

Vibration based Condition Montioring

Vibration-based predictive maintenance for high-impact rotating equipment, specifically the Kiln Shell, Vertical Roller Mills (VRM), Ball Mills, and Clinker Cooler Fans.

Substation & Power Monitoring

Comprehensive health tracking for Energy meters, Transformers, Relays, Breakers, Bus Bar temperature, ambient temperature, VFDs, and UPS systems to prevent electrical downtime.

Cyclone Healthiness Prediction

AI models to predict Cyclone Jamming and build-up rish in the pre-heater string to provide early warnings and prevent disruptive manual clean-outs.

Foreign Particle Monitoring

Automated vision scans material for metallic scrap, wood, or oversized boulders that could damage crushers, creating alerts and pausing the feed.

Conveyor Health Monitoring

AI cameras monitor the Clinker, Limestone Feed, and Coal Belts for mistracking or fraying to ensure a continuous, uninterrupted flow to the kiln.

Operational Safety & Compliance

Vision-Based Life Safety 24/7 automated vigilance for a zero-harm workplace

PPE Compliance Monitoring

Real-time detection of helmets and high-visibility vests across production and utility zones.

Logistics Safety

Automated tracking for equipment overspeeding in heavy traffic areas and material handling zones.

Red-Zone Intrusion

Instant AI alerts for personnel entering hazardous areas near the kiln or moving conveyor systems.

Hazardous Environment Monitoring

Continuous tracking for "man-down" scenarios, falls in remote sections, and early detection of hazardous dust or smoke emissions.

Real-time Incident Response

24/7 automated vigilance that replaces manual patrolling to ensure immediate reaction to safety protocol deviations.

Serving the Entire Spectrum of Cement

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Your Partners in Industrial Transformation

Discover how Faclon delivers measurable value to every role from strategy to operations, maintenance, and the shop floor.
Vivek Singh
Solution Expert

Focused on delivering predictive analysis to anticipate performance trends, enabling predictive maintenance to minimize downtime, and applying anomaly detection to identify risks before they disrupt operations.

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Siddharth Jha
Solution Expert

Expert in creating digital logbooks for seamless data capture, applying statistical process control for quality assurance, and using time series forecasting to optimize planning and operations.

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Vivek Jaiswal
Solution Expert

Specializes in managing water systems with digital intelligence, delivering accurate renewable energy forecasting, and providing deep RHT insights to improve efficiency, reliability, and sustainable industrial operations.

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Archit Naraniwal
Regional Director

Expert in optimizing machine health with predictive insights, bridging IT-OT systems for seamless operations, and forecasting energy demand to ensure efficiency, reliability, and smarter decision-making at scale.

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Parth Chaudhary
Regional Director

Focused on driving energy visibility across plants, improving utilities efficiency with actionable insights, and ensuring reliable operations through advanced OEE monitoring and performance tracking.

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Parag Patil
Regional Director

Expert in optimizing HVAC chillers and standalone units for peak efficiency while enabling advanced solar monitoring to ensure energy reliability, sustainability, and smarter performance across industrial operations.

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Kapil Dev
Senior Sales Representative

Specializes in delivering OEE insights for productivity improvement, enabling seamless PLC control for automated processes, and streamlining CMMS workflows to enhance maintenance efficiency and reduce downtime.

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Hitesh Choudhary
Solution Expert

Specializes in building digital twin solutions that accurately mirror real-world operations, while enabling end-to-end traceability to improve quality, compliance, efficiency, and transparency across complex industrial processes.

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Rajveer Singh
Solution Expert

Expert in applying vision analytics to measure particle size, monitor conveyors, detect quality defects, and ensure safety compliance - enabling smarter operations with reliable, real-time visual intelligence.

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