Overview
A major cement producer in Canada wanted to offer more customized cement blends to meet changing customer demand. The company’s existing plant was designed mainly for large-volume, standard cement production, which made it difficult to create small specialty batches. As the market shifted toward project-specific and boutique cement blends, the producer began losing opportunities to third-party terminals that had more flexible blending systems.
To solve this problem, the producer partnered with Cyclonaire to add a new cement blending system to the existing silo and loadout structure. The goal was to create a fast, accurate, and reliable way to make custom blends without disrupting normal operations. The new system was designed to pull material from multiple silos, calculate blend ratios precisely, and deliver consistent product directly to truck loadout or back into storage when needed.
Solutions
The blending system introduced recipe controls for repeatable blends, a quality control sample port for checking product quality, and integration with the plant’s ERP system for better visibility into sales and inventory. This combination of hardware and controls allowed the producer to respond quickly to specific customer requests while maintaining accurate records for every batch produced.
Installation of the system began in August 2023 and was completed by December 2024. Early production runs confirmed that the system performed as expected. The producer’s team, including senior leadership, was pleased with the accuracy and reliability of the blends. Laboratory testing verified that the system met the company’s quality requirements and supported ongoing commercial production.
Results
By implementing this cement blending system, the producer can now supply custom blends that were previously unavailable at the site. This new capability helps recover lost business, strengthens the company’s competitive position, and supports new revenue growth. The system also improves operational efficiency by streamlining batching, improving data visibility, and reducing the need to rely on third-party blending terminals. Overall, it creates a strong foundation for long-term growth as the cement market continues to move toward specialized products.
To view the full case study, please fill out the form below.