Polysius

Making relevant information available faster.

Enable earlier insights.

Support more stable plant operation.

Laboratory automation is a key lever for improving overall plant performance in modern cement plants.

The laboratory is no longer an isolated support function, but a critical source of information that directly influences product quality, process stability and operating costs. By providing reliable and timely data, laboratory automation supports better decision-making across the entire plant operation.

From sample handling and preparation to analysis and data management, laboratory automation makes quality-relevant information available faster and more consistently. This reduces the time lag between material or process changes and corrective actions. Instead of reacting to quality deviations days or weeks later, plant operators gain earlier insights that enable a more stable, data-driven operation.

As a result, laboratory automation improves feedback on material and process changes, supports higher plant stability through earlier quality insights and reduces the risk of unnoticed efficiency losses. At the same time, it enables stronger integration of laboratory data into daily plant operation, helping cement producers maintain consistent quality and stable performance.

1.

AUTOMATIC SAMPLING FROM
THE PRODUCTION PROCESS

Material is continuously collected from the production line via automatic sampling stations and transferred to the laboratory.

2.

SAMPLE RECEIVING AND PREPARATION polab® AMT
Samples are handled fully automatically, where a robotic system manages sample receiving and preparation in a controlled and reproducible manner for laboratory analysis.

3.

STANDARD ANALYTICAL METHODS (XRF / XRD)

Prepared samples are analysed using established analytical techniques to determine chemical and mineralogical properties.

4.

AUTOMATED REACTIVITY  MEASUREMENT polab® CAL

Samples are transferred to polab® Cal, where automated isothermal calorimetry provides fast, reproducible reactivity data under stable temperature conditions.

5.

DIGITAL QUALITY AND PROCESS CONTROL (AQCNET)
All analytical results are consolidated within the AQCnet software system and can be used to support quality assurance and process control decisions.

Case Study

Integration of polab® Cal

into a Laboratory Set-up

We integrated an automated isothermal calorimeter system (polab® Cal) into a laboratory environment of a cement plant in Germany. The system forms part of the plant’s quality control setup and is designed to operate during ongoing production.

During production, material is collected through automatic sampling stations, homogenized and transferred to the central laboratory. Samples are received by the polab® AMT system, prepared under controlled conditions and then routed to established analytical methods such as XRF and XRD. For reactivity measurements, samples are transferred to polab® Cal, where automated isothermal calorimetry is carried out in a temperature-controlled enclosure. This ensures stable thermal conditions for analyzing early hydration reactions of cement and clinker.

The plant operates two mills during normal production, each providing samples on an hourly basis. Depending on the material type and selected analysis duration, the automated calorimeter can process multiple samples per hour and is designed for unattended operation.

KEY BENEFITS

FAQ

How does the polab® system improve process stability?

polab® automates sampling, transport, and analysis, eliminating human error and providing representative data in real-time. This precision allows for the optimization of raw material mixes and maintains high product quality, leading to a significant reduction in OPEX and an excellent ROI.

The polab® AMT is thyssenkrupp’s robotic laboratory automation system. It integrates the existing polab® standard modules for capsule reception and sample preparation into a successful modular design. Due to the reach of the robot, components are arranged in a circular fashion. The polab® AMT is available in both standard and large size, with the larger option housing up to four pneumatic tube receivers, four polab® APM mill/press units, a double storage system, and a range of other components such as 2 granulometers. In its maximum configuration, the AMT is capable to handle even the largest cement plants with a sample throughput of up to 32 samples per hour. The polab® AMT is controlled via an included tablet computer mounted on the housing, or from any mobile device or computer connected to the system. Internally, a central dedusting system keeps the laboratory clean and reduces the need for cleaning and daily maintenance.

Automated isothermal calorimetry delivers real-time reactivity data that enables measurement-based process decisions and stabilizes cement production as clinker content decreases and material variability increases. polab® Cal provides immediate feedback (under 60 minutes) that supports precise process adjustments (e.g., separator speed), helping reduce the clinker factor and improve energy‑efficient, sustainable production.

Learn more about optimizing your plant:
Modernization Portfolio Deep Dive

In a rapidly evolving industrial landscape, staying competitive means getting more out of the assets you already have. During our upcoming 30–45 minute virtual session, we will show how targeted modernizations can unlock hidden performance potential across your plant, boosting throughput, improving efficiency, and reducing OPEX.

Join our experts from thyssenkrupp Polysius as they provide a compact, high‑value overview of modernization levers across the entire process chain:  crushing, raw grinding, clinker grinding, pyroprocessing, and laboratory automation.

YOU’LL GAIN INSIGHTS INTO: 

WHAT TO EXPECT:

Matthias Hettinger

Head of Sales, Digital, Automation & polab

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Polysius

About us

athyssenkrupp Polysius is one of the leading suppliers of technologies and automation solutions for the decarbonization of the cement and lime industry and, increasingly, for other industries. With more than 160 years of experience, we set standards in the development of innovative technologies and services, as well as a comprehensive and customized service offering that enables sustainable and economical production.

Our services are not only tailored to our own products, but also cover installations from third-party suppliers. Thanks to close cooperation with customers and partners, we are able to meet the specific challenges of our customers and offer them optimal service. This special commitment, coupled with decades of expertise, makes thyssenkrupp Polysius a reliable partner on the road to a sustainable future.

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