If you are the kind of professional that is always looking into the latest cutting-edge technology and ways to implement it in your cement and mining applications, well… this article is for you.
IoT sensors are revolutionizing how maintenance is performed in cement plants. Predictive maintenance—enabled by real-time data from connected sensors—means you can fix stuff before it breaks. This transition not only saves money on repairs and energy but also increases equipment lifespan and improves overall plant efficiency.
Besides, you will get the pulse of your plant at all times. 24/7/365!
A typical cement plant goes through several important steps to make cement. First, extractors remove raw materials from the quarry. Then, crushers and mills break down large rocks into smaller pieces. These are mixed in the right amounts using blenders and mixers, and then finely ground in grinders. The mixture is heated and cooled in a large rotating kiln. Finally, the finished cement is packed and sent out using conveyor belts or trucks.
Throughout the whole process, systems like dust control, silo management, motors, fans, and conveyors play a vital role in keeping everything running smoothly.
Here’s how different IoT sensors can make your dust collection system smarter and more efficient in 2025.
Baghouse.com is teaming up with Senzary to offer advanced IoT sensors that will take your dust collection and plant maintenance to the next level.
We are excited to collaborate with this renowned company, and thrilled with the many possibilities to bring the Internet of Things to create Smart Plants, not only to the cement industry, but also all other dust collection applications.
The Power of Sensor-Driven Maintenance
In modern cement plants and other industries, sensor-based maintenance is transforming equipment upkeep:
- ✅ Predictive Insights: Advanced sensors continuously monitor your machinery, detecting subtle changes that indicate potential issues before they escalate into costly breakdowns.
- ✅ Data-Driven Decisions: Real-time data from strategically placed sensors empowers you to make informed maintenance decisions, optimizing your equipment’s performance and lifespan. By identifying maintenance needs precisely, you can schedule interventions during planned downtimes, minimizing disruptions to your operations.
- ✅ Cost Reduction: Sensor-based maintenance significantly reduces unnecessary repairs and replacements, lowering your overall maintenance costs.
How Does this Technology Work?
In a cement plant, IoT sensors are installed on critical equipment to monitor parameters like temperature, vibration, and pressure in real time. These low-power sensors transmit data wirelessly to gateways using robust radio technologies such as LoRaWAN. The gateways securely send the data to a cloud-based platform like IoTLogIQ, where it’s organized and processed through a network layer. The system then provides actionable insights through a user-friendly dashboard, enabling plant operators to detect issues early, plan predictive maintenance, and reduce unexpected downtime while improving overall efficiency and safety.
Essential Sensors for Your Dust Collection System
Particulate Matter Sensors (DustIQ)
Undetected leaks in a baghouse can lead to emissions violations and efficiency losses. Advanced sensors can detect leaks early, ensuring that maintenance teams address the issue promptly before it leads to significant performance declines or regulatory fines.
These sensors continuously monitor the dust concentration in exhaust air. Most leaking baghouse filters begin as small holes or rips that overtime become worse and worse. DustIQ provides real- time monitoring of dust levels and filter performance.
- 🔶 It’s simple to install, you just need to place it on your equipment without any wiring or configuration.
- 🔶 It’s autonomous, it works for several months without recharging.
- 🔶 It’s secure by design, its designed for harsh or even explosive environments.
The enLink Air LoRa wireless Air Quality Monitor is a high-precision device that measures up to 14 important environmental conditions.
The enLink Air LoRa wireless Air Quality Monitor is a high-precision device that measures up to 14 important environmental conditions. These include temperature, humidity, light level, volatile organic compounds (VOCs), carbon dioxide (CO₂), fine and coarse dust particles (PM2.5 and PM10), oxygen, sound level, and barometric pressure. It can also connect to 4 extra plug-in gas sensors, choosing from over 200 different gas types or sensitivity levels. The monitor sends real-time data to the cloud using long-range LoRa wireless technology, so the information can be viewed and analyzed from anywhere.
Auburn Filtersense PM series probes
Virtually any sensor with the capability to send a digital signal can be integrated with the IOT software and system. For example, the Auburn Filtersense PM series probes with 4-20mA outputs can also be integrated if you need this particular style of broken bag detection.
Differential Pressure Sensors
Monitoring the pressure difference across filter bags or cartridges is important to know how well the filters are working. If the pressure slowly goes up, it usually means the filters are getting clogged. If the pressure suddenly drops, it might mean a filter has failed. Real-time alerts help maintenance teams act quickly—cleaning or changing filters before they create bigger problems. This helps save energy and avoid unplanned shutdowns.
The EnLink Status-DP uses long-range LoRa wireless to measure and send differential pressure data, even from up to 16 km away.
The EnLink Status-DP makes this easy by using long-range LoRa wireless to measure and send differential pressure data, even from up to 16 km away. It can be used to track pressure before and after filters. It runs on a long-life battery, making installation simple and low-cost. Its special Multi-Range sensor includes up to 7 calibrated pressure ranges, so one Status-DP unit can handle a wide range of pressure monitoring needs.
Airflow Sensors
Airflow sensors help detect blockages in the ductwork or issues with the fan. If airflow drops below the ideal level, operators can respond quickly to fix the problem and keep the system running smoothly.
The enLink Status-AF focuses specifically on airflow, measuring air velocity from 0 to 40 m/s with extremely high accuracy of 0.1%.
The enLink Status-AF focuses specifically on airflow, measuring air velocity from 0 to 40 m/s with extremely high accuracy of 0.1%. Like the other enLink devices, it transmits data using LoRa wireless for easy cloud integration or connection to onsite systems via Modbus IP, enabling performance tracking and real-time alerts.
Temperature and Humidity Sensors
High humidity can cause dust to stick together and clog filters, while very high or low temperatures can shorten the life of equipment. By monitoring these conditions, plants can make adjustments to avoid damage and maintain system efficiency.
The Dragino LSN50v2-S31 is a LoRaWAN wireless sensor designed to accurately measure temperature and humidity in the surrounding environment.
The Dragino LSN50v2-S31 is a LoRaWAN wireless sensor designed to accurately measure temperature and humidity in the surrounding environment. It uses the SHT31 sensor from Sensirion, which is fully calibrated, temperature compensated, and known for its reliability and long-term stability. The sensor is housed in a waterproof, anti-condensation casing, making it suitable for long-term use. It can also send alerts if temperature or humidity goes beyond set limits. Powered by an 8500mAh Li-SOCI2 battery, it’s built to last up to 10 years depending on usage and update frequency, making it a reliable, low-maintenance monitoring solution for industrial environments.
Rotating Machine Monitoring (RotaryIQ)
RotaryIQ monitors and analyses any rotating machine and helps to automate diagnostics and predict anomalies, wirelessly and non-intrusively, with a simple installation. Sensors communicate through LoRaWan (Long range network) and data is encrypted end-to-end. Senzary’s sensors monitor not only heat and vibration, but ultrasound too, meaning customers have the earliest possible alert of drift – before any damage has occurred.
- 🔶 Vibrations, temperature, humidity, 3-axial accelerometer: Looseness, imbalance, misalignment, advanced degradation.
- 🔶 Ultrasounds: Lubrication issues, early signs of rolling degradation, gas leaks.
Monitoring Material Inside Silos (SiloIQ)
The high-frequency signals (e.g., 80 GHz) and narrow beam angles (e.g., 15°) enable accurate targeting of the material surface, even with uneven topography or buildup on walls. Radar technology allows for non-intrusive measurement without contact with the abrasive cement material. This eliminates issues like sensor wear, maintenance, and contamination associated with contact-based methods.
Real-time level data from radar sensors provides up-to-date information on material inventory in each silo. This enables better production planning, timely replenishment, and avoidance of costly run-outs or overfills. It also can optimize material usage, production scheduling, and logistics. Radar performs well in challenging silo geometries found in cement plants, including tall and narrow silos, large bunkers, and dome-shaped storage halls.
The Advantage of Smart Sensors In Your Cement Plant
Choosing an advanced IoT solution for the maintenance needs of your cement plant means benefiting from:
- ✅ Custom sensor networks aligned with your specific equipment, industry requirements, and operational goals.
- ✅ AI-powered analytics that translate complex sensor data into actionable maintenance insights.
- ✅ Sensors and software that integrate smoothly with existing maintenance management systems.
- ✅ The ability to start with critical assets and expand sensor networks as operational needs grow.
- ✅ Ongoing assistance from maintenance and IoT specialists to ensure maximum benefits from sensor-based maintenance programs.
Investing in IoT sensors is no longer an option—it’s a necessity for cement plants looking to remain competitive in 2025 and beyond.
If you’re a plant manager, operator, or engineer committed to pushing your facility to peak performance, now is the time to act. With each connected device, you’re not only protecting your equipment but unlocking the full potential of your plant. Don’t wait for failure—get ahead of it. Invest in intelligence, drive efficiency, and lead your plant into a new era of innovation, reliability, and profitability. The technology is here.
