A coalition of three leading digital innovators — Gigaton, alcemy, and CemAI – Cement Intelligence — has published a new white paper offering one of the most detailed roadmaps to date on how artificial intelligence can reshape the entire cement production chain. The publication, titled “From quarry to lorry: how AI is solving cement’s biggest production challenges,” outlines a practical, end‑to‑end framework for deploying AI across quarry operations, raw mix optimisation, pyroprocess control, quality management, and predictive maintenance.
A sector under pressure — and a technology with answers
Cement producers today face a convergence of challenges: volatile fuel markets, tightening emissions regulations, ageing equipment, and the constant pressure to maintain stable plant performance. Added to this is a new expectation from executive teams to “do something with AI,” even as many plants struggle to move beyond pilot projects.
The white paper argues that while AI is advancing rapidly in the mainstream, adoption in cement remains uneven — not because of lack of potential, but because producers often lack a clear, structured pathway from experimentation to measurable operational gains.
A practical guide from three specialists across the value chain
The publication brings together the combined expertise of three companies working at different stages of cement and concrete production. It outlines the foundational prerequisites for successful AI deployment:
- Clean, connected data
- Domain expertise in the right places
- A committed on‑site champion to drive adoption
These elements form the backbone of any AI programme capable of delivering real value.
The guide then breaks down how AI can be applied across the production chain:
Predictive maintenance (CemAI)
CemAI’s cement‑specific machine learning models detect equipment anomalies early, prevent unplanned shutdowns, and identify process inefficiencies that would otherwise remain hidden.
Process optimisation (Gigaton)
Gigaton’s AI tools maximise thermal substitution rates, increase alternative fuel use, reduce emissions, and stabilise kiln operations through real‑time optimisation — improving throughput and lowering costs.
Predictive quality management (alcemy)
alcemy’s platform enhances quality consistency, enabling producers to reduce production costs, increase throughput, and progressively lower the CO₂ footprint without compromising clinker quality.
Driving long‑term adoption
The white paper also addresses the human side of digital transformation: leadership structures, communication strategies, and change‑management approaches that turn a successful pilot into sustained, plant‑wide use.
Real‑world deployments and industry momentum
The release coincides with a major milestone for Gigaton — formerly Carbon Re — which recently closed a US$26 million Series A funding round. Its AI systems are already deployed at plants operated by Adani Cement, Heidelberg Materials, and Holcim, where early results show more than US$1 million in annual savings per plant.
These real‑world case studies form the evidence base for the white paper, demonstrating how AI can deliver tangible improvements in energy efficiency, clinker factor optimisation, emissions reduction, and equipment reliability.
Access the company resources
- Alcemy: https://www.alcemy.tech
- CemAI: https://www.cemai.com
- Gigaton: https://www.gigaton.ai
Source: World Cement (11 June 2026)
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Cementitious Materials International Technical & Trade Congress – Europe
28–29 October, Brussels, Belgium
A leading EMEA gathering on cementitious materials, market trends, regulatory updates, and regional opportunities.
CarbonZero Alternative Fuels & Raw Materials Global Conference & Exhibition 2026
Including Cementitious Europe – Congress
28–29 October, Brussels, Belgium
Global platform for Net Zero strategies, alternative fuels, raw materials, carbon capture, and emerging technologies.
Women in Cement and Construction International Congress 2026 – EMEA
30 October, Brussels, Belgium
A dedicated forum advancing diversity, equity, and inclusion across the cement and construction sectors.
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24 – 25 November, São Paulo, Brazil
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Industry 5.0 Global Conference & Exhibition 2026
24 – 25 November, São Paulo, Brazil
Hosted at the same venue and dates as the Sustainability Summit — two events for one price, one ticket, full access.
Cementitious Materials International Technical & Trade Congress – MEA
8–9 December, Morocco
The premier MEA event for cementitious materials, innovation, and regional trade opportunities.
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